U.S. patent number 8,084,713 [Application Number 11/828,505] was granted by the patent office on 2011-12-27 for method of and system for setting laser processing conditions, laser processing system, computer program for setting laser processing conditions, computer readable medium and recording device on which laser processing conditions are recorded.
This patent grant is currently assigned to Keyence Corporation. Invention is credited to Mamoru Idaka, Hideki Yamakawa.
United States Patent |
8,084,713 |
Idaka , et al. |
December 27, 2011 |
Method of and system for setting laser processing conditions, laser
processing system, computer program for setting laser processing
conditions, computer readable medium and recording device on which
laser processing conditions are recorded
Abstract
A method of setting processing data for a computer-assisted
laser processing apparatus is disclosed, along with a system for
setting a laser processing data. The method comprises a function of
setting a three-dimensional profile of a object and a processing
pattern as processing conditions, a function of generating
processing data representing the processing conditions for the
object, and a function of visually displaying a two dimensional
representation of the processing data on a display screen and a
function of setting a three-dimensional profile of a object and a
processing pattern as processing conditions, wherein it is enabled
to set the three-dimensional profile and the processing pattern
while displaying the object in two dimensions on the display screen
disposed within a processing zone.
Inventors: |
Idaka; Mamoru (Osaka,
JP), Yamakawa; Hideki (Osaka, JP) |
Assignee: |
Keyence Corporation (Osaka,
JP)
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Family
ID: |
38985123 |
Appl.
No.: |
11/828,505 |
Filed: |
July 26, 2007 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20080023455 A1 |
Jan 31, 2008 |
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Foreign Application Priority Data
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Jul 27, 2006 [JP] |
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2006-204777 |
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Current U.S.
Class: |
219/121.83;
700/166 |
Current CPC
Class: |
B23K
26/03 (20130101); B23K 26/082 (20151001) |
Current International
Class: |
B23K
26/03 (20060101); G06F 19/00 (20060101) |
Field of
Search: |
;219/121.62,121.68,121.83,121.67,121.69,121.72
;700/166,180,184 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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62263889 |
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Nov 1987 |
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JP |
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02198412 |
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Aug 1990 |
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JP |
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11028586 |
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Feb 1999 |
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JP |
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2000-202655 |
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Jul 2000 |
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JP |
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2003136260 |
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May 2003 |
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JP |
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2005-175566 |
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Jun 2005 |
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JP |
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2006-7257 |
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Jan 2006 |
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JP |
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2005046926 |
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May 2005 |
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WO |
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WO-2006/061959 |
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May 2006 |
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WO |
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Other References
Machine translation of Japan Patent No. 2005-175,566-A, Feb. 2011.
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Office Action issued by the U.S. Patent and Trademark Office in
corresponding U.S. Appl. No. 11/585,356 dated Nov. 9, 2010 (22
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Office Action issued by the U.S. Patent and Trademark Office in
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nineteen pages. cited by other.
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Primary Examiner: Evans; Geoffrey S
Attorney, Agent or Firm: Kilyk & Bowersox, P.L.L.C.
Claims
What is claimed is:
1. A laser processing system for processing a work surface within a
working area with a predetermined processing pattern by the use of
a laser beam, said laser processing system comprising: laser
generating means for generating a laser beam for processing;
scanning means for scanning a work surface with said laser beam
within a scanning area which is defined as a working area by a
scannable extent of said scanning means; said scanning means
comprising: a beam expander for varying a distance at which said
laser beam generated by said laser generating means is focused; a
first scanner for deflecting said laser beam coming from said beam
expander in a first direction to scan said work surface within said
scanning area in said first direction; and a second scanner for
deflecting said laser beam reflected by said first scanner in a
second direction perpendicular to said first direction to scan said
work surface within said scanning area in said second direction;
control means for controlling said a laser generating means and
said scanning means so as to process said work surface according to
laser processing conditions; processing pattern setting means for
setting as said laser processing conditions a processing pattern
and a position of said processing pattern within said scanning
area; work setting means for setting as said laser processing
conditions a three-dimensional profile of said work surface;
two-dimensional display means for displaying at least said scanning
area and said processing pattern in two-dimensions according to
said position within said scanning area; data generating means for
generating laser processing data for said work surface according to
said laser processing conditions; and three-dimensional display
means for displaying said scanning area in three-dimensions as well
as said three-dimensional profile of said work surface superimposed
on said scanning area based on data representing said processing
pattern and said position of said processing pattern set by said
processing pattern setting means and said three-dimensional profile
of said work surface set by said work setting means; wherein said
processing pattern setting means is enabled to reposition said
processing pattern superposed on said work surface within said
scanning area displayed on said three-dimensional display
means.
2. The laser processing system as defined in claim 1, wherein said
work setting means selects said three-dimensional profile of said
work surface from a plurality of predetermined three-dimensional
profiles.
3. The laser processing system as defined in claim 2, wherein said
plurality of predetermined different profiles include at least a
circular conical profile, a cylindrical columnar profile and a
spherical profile.
4. The laser processing system as defined in claim 1, wherein said
processing pattern setting means is capable of collectively setting
a plurality of processing patterns in a group and also setting as
said laser processing conditions each said processing pattern and a
position of each individual said processing pattern.
5. The laser processing system as defined in claim 4, wherein said
work setting means is capable of setting as said laser processing
conditions a three-dimensional profile of said work surface
according to each individual said processing pattern.
6. The laser processing system as defined in claim 1, and further
comprising view point changing means for rotating said scanning
area displayed in two dimensions so as thereby to change a view
point of a three-dimensional display on said three-dimensional
display means.
7. The laser processing system as defined in claim 6, wherein said
three-dimensional display means shows a three-dimensional display
of a direction of radiation of said laser beam.
8. The laser processing system as defined in claim 7, wherein said
three-dimensional display means shows a three-dimensional display
of an icon indicating a part of said scanning means from which said
laser beam is radiated.
9. The laser processing system as defined in claim 1, and further
comprising position changing means for shifting a position of said
work surface and said processing pattern integrally with said work
surface within said scanning area displayed in said
three-dimensional display means.
10. The laser processing system as defined in claim 1, wherein said
work setting means is capable of setting an angle of rotation of
said work surface with respect to each axis of three-dimensional
coordinate system of said three-dimensional display means and said
three-dimensional display means displays said work surface after a
rotation through said angle of rotation.
11. The laser processing system as defined in claim 1, wherein said
work setting means uses a pre-created data file to set a
three-dimensional profile of said work surface.
12. The laser processing system as defined in claim 1, further
comprising size setting means for varying a size of said work
surface displayed within said scanning area on said
three-dimensional display means.
13. The laser processing system as defined in claim 1, wherein said
work setting means specifies either one of inner and outer sides of
said profile of said work surface for processing.
14. The laser processing system as defined in claim 1, wherein said
three-dimensional display means is capable of displaying said work
surface in three dimensions selectively in an X-Y coordinate plane,
a Y-Z coordinate plane and a Z-X coordinate plane.
15. The laser processing system as defined in claim 1, and further
comprising defective surface area detection means for detecting a
defective work surface area of said work surface that is an area of
said work surface hidden from laser beam radiation and a defective
work surface area of said work surface that is an area of said work
surface exposed to laser beam radiation at an angle within a
predetermined range of angle depending upon at least said laser
processing conditions set by said work setting means and warning
means for hiding said processing pattern from said two-dimensional
display means when said processing pattern overlaps at least partly
said defective work surface area.
16. A laser processing data setting system for setting processing
data based on a processing pattern with which a laser processing
system having scanning means processes a work surface within a
working area, which is a scanning area defined in one direction by
a first scannable extent of said scanning means and in another
direction orthogonal with said one direction by a second scannable
extent of said scanning means, according to laser processing
conditions with a laser beam, said laser processing data setting
system comprising: processing pattern setting means for setting as
said processing conditions a processing pattern and a position of
said processing pattern within a scanning area; work setting means
for setting as laser processing conditions a three-dimensional
profile of said work surface; two-dimensional display means for
displaying at least said scanning area and said processing pattern
in two-dimensions according to said position within said scanning
area; data generating means for generating laser processing data
for said work surface according to said laser processing
conditions; and three-dimensional display means for displaying said
scanning area in three-dimensions as well as said three-dimensional
profile of said work surface superimposed on said scanning area
based on data representing said processing pattern and said
position of said processing pattern set by said processing pattern
setting means and said three-dimensional profile of said work
surface set by said work setting means; wherein said processing
pattern setting means is enabled to reposition said processing
pattern superposed on said work surface within said scanning area
displayed on said three-dimensional display means.
17. The laser processing system as defined in claim 16, wherein
said work setting means selects said three-dimensional profile of
said work surface from a plurality of predetermined
three-dimensional profiles.
18. The laser processing system as defined in claim 17, wherein
said plurality of predetermined different profiles include at least
a circular conical profile, a cylindrical columnar profile and a
spherical profile.
19. The laser processing system as defined in claim 16, wherein
said processing pattern setting means is capable of collectively
setting a plurality of processing patterns in a group and also
setting as said laser processing conditions each said processing
pattern and a position of each individual said processing
pattern.
20. The laser processing system as defined in claim 19, wherein
said work setting means is capable of setting as said laser
processing conditions a three-dimensional profile of said work
surface according to each individual said processing pattern.
21. The laser processing system as defined in claim 16, further
comprising view point changing means for rotating said scanning
area displayed in two dimensions so as thereby to change a view
point of a three-dimensional display on said three-dimensional
display means.
22. The laser processing system as defined in claim 21, wherein
said three-dimensional display means shows a three-dimensional
display of a direction of radiation of said laser beam.
23. The laser processing system as defined in claim 22, wherein
said three-dimensional display means shows a three-dimensional
display of an icon indicating a part of said scanning means from
which said laser beam is radiated.
24. The laser processing system as defined in claim 16, further
comprising position changing means for shifting a position of said
work surface and said processing pattern integrally with said work
surface within said scanning area displayed in said
three-dimensional display means.
25. The laser processing system as defined in claim 16, wherein
said work setting means is capable of setting an angle of rotation
of said work surface with respect to each axis of three-dimensional
coordinate system of said three-dimensional display means and said
three-dimensional display means displays said work surface after a
rotation through said angle of rotation.
26. The laser processing system as defined in claim 16, wherein
said work setting means uses a pre-created data file to set a
three-dimensional profile of said work surface.
27. The laser processing system as defined in claim 16, further
comprising size setting means for varying a size of said work
surface displayed within said scanning area on said
three-dimensional display means.
28. The laser processing system as defined in claim 16, wherein
said work setting means specifies either one of inner and outer
sides of said profile of said work surface for processing.
29. A method of setting laser processing data according to a
processing pattern based on which a laser processing system
processes a work surface within a working area with said processing
pattern by the use of a laser beam, said laser processing data
setting method comprising the steps of: displaying a work surface
within a working area in two dimensions in a two-dimensional
display screen on display means; setting as laser processing
conditions a three-dimensional profile of said work surface and a
processing pattern and a position of said processing pattern within
said working area while a two-dimensional display of a work surface
disposed within a working area, that is a scan area defined in one
direction by a first scannable extent of a scanning means and in
another direction orthogonal with said one direction by a second
scannable extent of said scanning means, is shown within said
two-dimensional display screen on said display means; and
displaying said work surface by either way of switching said
two-dimensional display in said two-dimensional display screen into
a three-dimensional display and providing a three-dimensional
display screen on said display means showing a three-dimensional
display of said work surface therein while showing said
two-dimensional display of said work surface in said
two-dimensional display screen.
30. The method of setting laser processing data as defined in claim
29, wherein said three-dimensional profile of said work surface is
selected from a plurality of predetermined three-dimensional
profiles.
31. The method of setting laser processing data as defined in claim
30, wherein said plurality of predetermined different profiles
include at least a circular conical profile, a cylindrical columnar
profile and a spherical profile.
32. The method of setting laser processing data as defined in claim
29, wherein a plurality of processing patterns are collectively set
in a group and each said processing pattern and a position of each
individual said processing pattern are also set as said laser
processing conditions.
33. The method of setting laser processing data as defined in claim
32, wherein a three-dimensional profile of said work surface is set
as said laser processing conditions according to each individual
said processing pattern.
34. The method of setting laser processing data as defined in claim
29, further comprising the step of rotating said scanning area
displayed in two dimensions so as thereby to change a view point of
a three-dimensional display on said three-dimensional display
screen.
35. The method of setting laser processing data as defined in claim
34, further comprising the step of showing a three-dimensional
display of a direction of radiation of said laser beam in said
three-dimensional display screen.
36. The method of setting laser processing data as defined in claim
35, further comprising the step of showing a three-dimensional
display of an icon indicating a part of said scanning means from
which said laser beam is radiated in said three-dimensional display
screen.
37. The method of setting laser processing data as defined in claim
29, and further comprising the step of shifting a position of said
work surface and said processing pattern integrally with said work
surface within said scanning area displayed in said display
means.
38. The method of setting laser processing data as defined in claim
29, further comprising the steps of setting an angle of rotation of
said work surface with respect to each axis of three-dimensional
coordinate system of three-dimensional display screen and
displaying said work surface after a rotation through said angle of
rotation.
39. The method of setting laser processing data as defined in claim
29, wherein a pre-created data file is used to set a
three-dimensional profile of said work surface.
40. The method of setting laser processing data as defined in claim
29, further comprising the step of varying a size of said work
surface displayed within said scanning area in said
three-dimensional display screen.
41. The method of setting laser processing data as defined in claim
29, further comprising the step of specifying either one of inner
and outer sides of said profile of said work surface for
processing.
42. A computer-readable storage medium that is non-transitory and
in which a computer program is stored for setting laser processing
data according to a processing pattern based on which a laser
processing system processes a work surface within a working area
with said processing pattern by the use of a laser beam, said
computer program for setting laser processing data comprising: a
function of displaying a work surface within a working area in two
dimensions in a two-dimensional display screen on display means; a
function of setting as laser processing conditions a
three-dimensional profile of said work surface and a processing
pattern and a position of said processing pattern within said
working area while a two-dimensional display of a work surface
disposed within a working area, that is a scan area defined in one
direction by a first scannable extent of a scanning means and in
another direction orthogonal with said one direction by a second
scannable extent of said scanning means, is shown within said
two-dimensional display screen on said display means; and a
function of displaying said work surface by either way of switching
said two-dimensional display in said two-dimensional display screen
into a three-dimensional display and providing a three-dimensional
display screen on said display means showing a three-dimensional
display of said work surface therein while showing said
two-dimensional display of said work surface in said
two-dimensional display screen.
43. The computer-readable storage medium as defined in claim 42,
wherein said three-dimensional profile of said work surface is
selected from a plurality of predetermined three-dimensional
profiles.
44. The computer-readable storage medium as defined in claim 43,
wherein said plurality of predetermined different profiles include
at least a circular conical profile, a cylindrical columnar profile
and a spherical profile.
45. The computer-readable storage medium as defined in claim 42,
wherein a plurality of processing patterns are collectively set in
a group and each said processing pattern and a position of each
individual said processing pattern are also set as said laser
processing conditions.
46. The computer-readable storage medium as defined in claim 45,
wherein a three-dimensional profile of said work surface is set as
said laser processing conditions according to each individual said
processing pattern.
47. The computer-readable storage medium as defined in claim 42,
further comprising a function of rotating said scanning area
displayed in two dimensions so as thereby to change a view point of
a three-dimensional display on said three-dimensional display
screen.
48. The computer-readable storage medium as defined in claim 47,
further comprising a function of showing a three-dimensional
display of a direction of radiation of said laser beam in said
three-dimensional display screen.
49. The computer-readable storage medium as defined in claim 48,
further comprising a function of showing a three-dimensional
display of an icon indicating a part of said scanning means from
which said laser beam is radiated in said three-dimensional display
screen.
50. The computer-readable storage medium as defined in claim 42,
further comprising a function of shifting a position of said work
surface and said processing pattern integrally with said work
surface within said scanning area displayed in said
three-dimensional display means.
51. The computer-readable storage medium as defined in claim 42,
further comprising a function of setting an angle of rotation of
said work surface with respect to each axis of three-dimensional
coordinate system of three-dimensional display screen and a
function of displaying said work surface after a rotation through
said angle of rotation.
52. The method of setting laser processing data as defined in claim
42, wherein a pre-created data file is used to set a
three-dimensional profile of said work surface.
53. The computer-readable storage medium as defined in claim 42,
further comprising the step of varying a size of said work surface
displayed within said scanning area in said three-dimensional
display screen.
54. The computer-readable storage medium as defined in claim 42,
further comprising a function of specifying either one of inner and
outer sides of said profile of said work surface for
processing.
55. A computer program product directly loadable into an internal
memory of a computer, or stored on a computer-usable medium that is
non-transitory or a computer-readable medium that is
non-transitory, having a computer program stored thereon for
setting laser processing data according to a processing pattern
based on which a laser processing system processes a work surface
within a working area with said processing pattern by the use of a
laser beam, said computer program comprising: a function of
displaying a work surface within a working area in two dimensions
in a two-dimensional display screen on display means; a function of
setting as laser processing conditions a three-dimensional profile
of said work surface and a processing pattern and a position of
said processing pattern within said working area while a
two-dimensional display of a work surface disposed within a working
area, that is a scan area defined in one direction by a first
scannable extent of a scanning means and in another direction
orthogonal with said one direction by a second scannable extent of
said scanning means, is shown within said two-dimensional display
screen on said display means; and a function of displaying said
work surface by either way of switching said two-dimensional
display in said two-dimensional display screen into a
three-dimensional display and providing a three-dimensional display
screen on said display means showing a three-dimensional display of
said work surface therein while showing said two-dimensional
display of said work surface in said two-dimensional display
screen.
56. A computer program means for setting laser processing data
according to a processing pattern based on which a laser processing
system processes a work surface within a working area with said
processing pattern by the use of a laser beam, said computer
program means comprising: means for performing a function of
displaying a work surface within a working area in two dimensions
in a two-dimensional display screen on display means; means for
performing a function of setting as laser processing conditions a
three-dimensional profile of said work surface and a processing
pattern and a position of said processing pattern within said
working area while a two-dimensional display of a work surface
disposed within a working area, that is a scan area defined in one
direction by a first scannable extent of a scanning means and in
another direction orthogonal with said one direction by a second
scannable extent of said scanning means, is shown within said
two-dimensional display screen on said display means; and means for
performing a function of displaying said work surface by either way
of switching said two-dimensional display in said two-dimensional
display screen into a three-dimensional display and providing a
three-dimensional display screen on said display means showing a
three-dimensional display of said work surface therein while
showing said two-dimensional display of said work surface in said
two-dimensional display screen.
57. A laser processing system for processing a work surface within
a working area with a predetermined processing pattern by the use
of a laser beam, said laser processing system comprising: laser
generating means for generating a laser beam for processing;
scanning means for scanning a work surface with said laser beam
within a scanning area which is defined as a working area by a
scannable extent of said scanning means; said scanning means
comprising: a beam expander for varying a distance at which said
laser beam generated by said laser generating means is focused; a
first scanner for deflecting said laser beam coming from said beam
expander in a first direction to scan said work surface within said
scanning area in said first direction; and a second scanner for
deflecting said laser beam reflected by said first scanner in a
second direction perpendicular to said first direction to scan said
work surface within said scanning area in said second direction;
control means for controlling said laser generating means and said
scanning means so as to process said work surface according to
laser processing conditions; processing pattern setting means for
setting as said laser processing conditions a processing pattern
and a position of said processing pattern within said scanning
area; work setting means for setting as said laser processing
conditions a three-dimensional profile of said work surface;
two-dimensional display means for displaying at least a whole
extent of said scanning area and said processing pattern in
two-dimensions according to said position within said scanning
area; data generating means for generating laser processing data
for said work surface according to said laser processing
conditions; three-dimensional display means for displaying said
whole extent of scanning area in three-dimensions as well as said
three-dimensional profile of said work surface superimposed on said
scanning area based on data representing said processing pattern
and said position of said processing pattern set by said processing
pattern setting means and said three-dimensional profile of said
work surface set by said work setting means; and position adjusting
means for adjusting a position of said processing pattern on said
work surface displayed in said scanning area on said
three-dimensional display means.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of and a system for
setting processing conditions of a laser processing system such as
a laser marker which performs processing such as printing or
marking including characters, symbols and graphics on work with a
laser beam, a computer program for setting processing conditions
for a laser processing system, a computer-readable recording medium
or device on which laser processing conditions are recorded.
2. Description of Related Art
A laser processing system scans a given scan field of a subject
surface of works (work surfaces) such as components and finished
products with a laser beam to apply processing, such as printing
and marking of characters, symbols and/or graphics, to the work
surfaces. Referring to FIGS. 1 and 2 for the purpose of providing a
brief description of a configuration of a laser processing system
by way of example, the laser processing system comprises a laser
control unit 1, a laser output unit 2 and an input unit 3.
Excitation light generated by a laser excitation device 6 of the
laser control unit 1 excites a laser medium 8 of a laser oscillator
50 of the laser output unit 2. A laser beam L emanating from the
laser medium 8 is expanded in beam diameter by a beam expander 53
and reflected and directed toward a scanning means by a reflection
mirror. A two dimensional scanning means 9 deflects the laser beam
L so as to scan a work W in a given scan field, thereby processing,
e.g. marking or printing, the work W.
There has been known a laser processing system which is provided
with a two dimensional scanning device 9 as shown in FIG. 2. The
scanning device 9 comprises a pair of galvanic mirrors which form
an X-axis scanner 14a and a Y-axis scanner 14b, and a pair of
galvanic motors 51a and 51b to which the galvanic mirrors are
mounted for rotation. The X-axis scanner 14a and the Y-axis scanner
14b are arranged so that their axes of rotation perpendicularly
intersecting with each other and deflect an incoming laser beam so
as to scan a scan field in X and Y directions perpendicularly
intersect with each other. The scanning device 9 is provided with
focusing means such as an f.theta. lens system for focusing the
laser beam in a given scan field.
There has been known a laser processing system which is provided
with a three-dimensional scanning device 14 as shown in FIG. 3. The
scanning device 14 comprises a Z-axis scanner comprising a motor
driven lens system capable of varying its focal distance which is
referred to as a working distance in a direction of height of the
work.
It is usual to use a computer program in order to create three
dimensional laser processing data for implementation of three
dimensional processing, such as three dimensional printing, by the
laser processing system. However, because the three dimensional
processing data requires a greater number of parameters regarding
print locations as compared with two dimensional processing data,
it is hard for users experienced only in creating two-dimensional
laser processing data to create three dimensional processing data
by use of the laser processing data setting program just as they
intended.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a
method of and a laser processing condition setting system, and a
laser processing system which enables to check up on whether
settings are properly specified to let a processing pattern fall
within a processable surface area of a work.
The foregoing objects and features of the present invention are
accomplished by a laser processing system for processing a work
surface within a working area with a predetermined processing
pattern by the use of a laser beam. The laser processing system
comprises laser generating means for generating a laser beam,
scanning means for scanning a work surface with the laser bean
within a scanning area, control means for controlling the a laser
generating means and the scanning means so as to apply the laser
processing to the work surface according to laser processing
conditions, processing condition setting means for setting the
laser processing conditions by specifying a three-dimensional
profile of the work surface and a processing pattern, data
generating means for generating laser processing data for the work
surface according to the laser processing conditions; and display
means for displaying and editing a representation of the laser
processing data in two dimensions, wherein the scanning means
comprises a beam expander for varying a distance at which the laser
beam generated by the laser generating means is focused, a first
scanner for deflecting the laser beam coming from the beam expander
in a first direction to scan the work surface within the scanning
area in the first direction, and a second scanner for deflecting
the laser beam reflected by the first scanner in a second direction
perpendicular to the first direction to scan the work surface
within the scanning area in the second direction, and the
processing condition setting means is enabled to set a three
dimensional profile of the work surface and the processing pattern
while the work surface is displayed in two dimensions in the
display means.
The display means may be capable of changing a display of the work
surface from a two dimensional display to a three dimensional
display, displaying a display screen or window for displaying the
work surface in three dimensions while displaying the work surface
in two dimensions therein, or displays the work surface in two
dimensions in a scanning plane therein. Further, the display means
is capable of displaying the work surface in three dimensions
selectively in an X-Y coordinate plane, a Y-Z coordinate plane and
a Z-X coordinate plane.
The laser processing system may comprise switching means for
switching the display means between a three dimensional edit mode
in which three dimensional processing data is edited and a two
dimensional edit mode in which three dimensional processing data is
exclusively edited. The two dimensional edit mode is preferably
chosen by default when the laser processing system is activated.
Further, the laser processing system may comprises defective area
detection means for detecting a defective work surface area of the
work surface that is only defectively processable or unprocessable
with the laser beam under the printing conditions by making a
calculation based on the three-dimensional profile of the work
surface and an angle at which the laser beam is expected to impinge
onto the work surface, and warning means for hiding the processing
pattern specified by the processing condition setting means on the
display means when the processing pattern cuts across at least
partly the defective work surface area.
According to another embodiment, a data setting system for setting
processing data based on a processing pattern with which a laser
processing system processes a work surface within a working area
with a laser beam comprises processing condition setting means for
setting the laser processing conditions by specifying a
three-dimensional profile of the work surface and a processing
pattern, data generating means for generating laser processing data
for the work surface according to the laser processing conditions,
and display means for displaying and editing a representation of
the laser processing data in two dimensions, wherein the processing
condition setting means is enabled to set a three dimensional
profile of the work surface and the processing pattern while the
work surface is displayed in two dimensions in the display
means.
According to another embodiment, a method of setting laser
processing data according to a processing pattern based on which a
laser processing system processes a work surface within a working
area with the processing pattern by the use of a laser beam
comprises the steps of displaying a work surface within a working
area in two dimensions in a display screen three dimensional,
setting a three-dimensional profile of the work surface and a
processing pattern as the laser processing conditions while
displaying the work surface in two dimensions in the display
screen, and displaying the work surface in three dimensions by
either way of switching the work displayed in the display screen
from a two dimensional representation to a three dimensional
representation and displaying a three dimensional display screen
for displaying the work surface in three dimensions in the display
screen while displaying the work surface in two dimensions in the
display screen.
According to another embodiment, a computer program for setting
laser processing data according to a processing pattern based on
which a laser processing system processes a work surface within a
working area with the processing pattern by the use of a laser beam
comprises a function of displaying a work surface within a working
area in two dimensions in a display screen, a function of setting a
three-dimensional profile of the work surface and a processing
pattern as the laser processing conditions while displaying the
work surface in two dimensions in the display screen, and a
function of displaying the work surface in three dimensions by
either way of switching the work displayed in the display screen
from a two dimensional representation to a three dimensional
representation and displaying a three dimensional display screen
for displaying the work surface in three dimensions in the display
screen while displaying the work surface in two dimensions in the
display screen.
The computer-readable storage medium or a storage device carries a
computer program as set forth above stored therein. The
computer-readable storage medium includes magnetic disks such as
CD-ROM, CD-R, CD-RW, a flexible disk, a magnetic tape, DVD-ROM,
DVD-RAM, DVD-R, DVD+R, DVD-RW, DVD+RW, Blue-ray, (trade name), FD
and DVD; optical disks, magnetic optical disks, semiconductor
memories and other medium capable of storing a computer program.
The program includes a program which is downloaded through network
communications such as an internet as well as a program stored on
the storage medium. The storage medium includes dedicated or
multipurpose equipments in which the computer program is mounted in
a viable state in the form of software or firmware. Processing and
functions of the computer program may be executed by program
software which a computer executes The functions may further be
realized by hardware such as a predetermined gate array such as
FPGA and ASIC or in the mixed form of program software and a
partial hardware module which realizes hardware partially.
According to still another embodiment, a computer program product
directly loadable into an internal memory of a digital computer or
stored on a computer-usable medium or a computer-readable medium
has the computer program as set forth above stored thereon.
According to a further embodiment, a computer program means for
setting laser processing data according to a processing pattern
based on which a laser processing system processes a work surface
within a working area with the processing pattern by the use of a
laser beam comprises means for performing a function of displaying
a work surface within a working area in two dimensions in a display
screen, means for performing a function of setting a
three-dimensional profile of the work surface and a processing
pattern as the laser processing conditions while displaying the
work surface in two dimensions in the display screen, and means for
performing a function of displaying the work surface in three
dimensions by either way of switching the work displayed in the
display screen from a two dimensional representation to a three
dimensional representation and displaying a three dimensional
display screen for displaying the work surface in three dimensions
in the display screen while displaying the work surface in two
dimensions in the display screen.
The laser processing data setting system allows users to edit
three-dimensional laser processing data in two dimensions. As a
consequence, the laser processing data setting system enables even
users who are unfamiliar with three-dimensional data editing to
achieve complicated of processing data setting with a three
dimensional representation. Since the display means can be changed
between a two dimensional display mode and a three dimensional
display mode, or otherwise, can coincidentally display a two
dimensional representation and a three dimensional representation
of the processing data as appropriate, it is facilitated to perform
confirmatory operation according to data setting operation.
Furthermore, a two dimensional representation of the processing
data is displayed in plane, namely an X-Y plane, Y-Z plane and Z-X
plane, as viewed from a view point or a laser irradiation source,
it can be recognized how a processing pattern deforms or distorts.
For example, in the case where a barcode is printed on a
cylindrical or columnar work surface, it is easily recognized how
narrow spaces distort. A three dimensional representation of the
processing data can be quickly changed to a display in a desired
plane. This facilitates confirmatory operation of a view point. The
exclusive edit mode which excludes users from three dimensional
data editing and is enabled by default upon activation of the laser
processing data setting system is convenient for users who are
unfamiliar with three-dimensional data editing.
Detection of a warning about a defective work surface area of a
work and surface facilitates confirmatory operation as to whether a
processing pattern falls within a processable work surface area as
desired. The confirmatory operation which is made even during
processing data setting saves users the trouble of setting
processing data and enables users to efficiently achieve processing
data setting, so that a user-friendly environment for processing
data setting is realized.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present
invention will be clearly understood from the following detailed
description when reading with reference to the accompanying
drawings wherein same or similar parts or mechanisms are denoted by
the same reference numerals throughout the drawings and in
which:
FIG. 1 is a block diagram schematically illustrating a laser
processing system according to an embodiment;
FIG. 2 is a perspective view showing a layout of an X-Y
scanner;
FIG. 3 is a perspective view showing a layout of X-axis, Y-axis and
Z-axis scanners;
FIG. 4 is a perspective view showing an internal arrangement of a
laser excitation unit;
FIG. 5 is a perspective view of a marking head including the laser
beam scanner of a laser marking system according to an embodiment
of the present invention;
FIG. 6 is a perspective rear view of the marking head;
FIG. 7 is a side view of the marking head;
FIG. 8A is an illustration showing a scan line of a laser beam with
respect to a work surface;
FIG. 8B is an illustration showing a corrected scan line of a laser
beam with respect to a work surface;
FIG. 9 is a side view of the laser beam scanner with a laser beam
adjusted at a long focal distance;
FIG. 10 is a side view of the laser beam scanner with a laser beam
adjusted at a short focal distance;
FIGS. 11A and 11B are front and side views of the Z-axis scanner,
respectively;
FIG. 12 is a schematic block diagram illustrating a laser marker
system capable of printing in three dimensions;
FIG. 13A is a schematic block diagram illustrating a system
architecture of a laser processing data setting system;
FIG. 13B is a schematic block diagram illustrating a variation of
the system architecture shown in FIG. 13A;
FIG. 13C is a schematic block diagram illustrating another
variation of the system architecture shown in FIG. 13A;
FIG. 14 is a photographic illustration showing a user interface
window, namely an edit display window, of a laser processing data
setting program which displays an object in a 2D edit mode;
FIG. 15 is a photographic illustration of the edit display window
which displays three print blocks;
FIG. 16 is a photographic illustration of an edit display window in
which a broken line is chosen as operation of a processing
apparatus;
FIG. 17 is a photographic illustration of an edit display window in
which a counterclockwise circle/ellipse is chosen as operation of a
processing apparatus;
FIG. 18 is a photographic illustration of the edit display window
shown in FIG. 67 which is changed to a 3D edit mode;
FIG. 19 is a photographic illustration of the edit display window
for specifying a data file;
FIG. 20 is a photographic illustration of the edit display window
for specifying a print patter;
FIG. 21 is a photographic illustration of the edit display window
for laying out print blocks;
FIG. 22 is a photographic illustration of the edit display window
for displaying a print block list;
FIG. 23 is a photographic illustration of the edit display window
in which a plurality of print blocks which are subject to batch
transformation;
FIG. 24 is a photographic illustration showing a 3D profile batch
transformation dialog box;
FIG. 25 is a photographic illustration showing a edit display
window in which print blocks are batch transformed according to
settings specified in the 3D profile batch transformation dialog
box shown in FIG. 24;
FIG. 26 is a photographic illustration of the edit display window
in which a plurality of print blocks are displayed I two
dimensions;
FIG. 27 is a photographic illustration of the edit display window
in which the print blocks shown in FIG. 57 are displayed in three
dimensions;
FIG. 28 is a photographic illustration of the edit display window
in which print blocks are displayed in two dimensions;
FIG. 29 is a photographic illustration of the edit display window
in which print patterns are unified into a block by the use of a
mouse;
FIG. 30 is a photographic illustration of the edit display window
in which print blocks are grouped by the use of a pop-up menu;
FIG. 31 is a photographic illustration of the edit display window
in which a print block is specified;
FIG. 32 is a photographic illustration of the edit display window
in which the print block shown in FIG. 31 is displayed in three
dimensions;
FIG. 33 is a photographic illustration of the edit display window
in which a plurality of print blocks separated away from one
another are grouped;
FIG. 34 is a photographic illustration of the edit display window
in which a plurality of print blocks are grouped;
FIG. 35 is a photographic illustration showing a print pattern when
an inclined surface is specified as a print surface;
FIG. 36 a photographic illustration showing the inclined surface
specified as a print surface in FIG. 35;
FIG. 37 is a photographic illustration of the edit display window
switched to a 3D edit mode from a 2D edit mode shown in FIG.
14;
FIG. 38 is a photographic illustration of the edit display window
in which a columnar work is selected and displayed;
FIG. 39 is a photographic illustration of the edit display window
for laying out print blocks;
FIG. 40 is a photographic illustration of the edit display window
in a 3D view mode in which a work is displayed as viewed obliquely
from above;
FIG. 41 is a photographic illustration of the edit display window
in a 3D view mode in which a work is displayed as viewed from
rear;
FIG. 42 is a photographic illustration of the edit display window
in a 3D view mode which is scrolled left;
FIG. 43 is a photographic illustration of the edit display window
in a 3D view mode which is scrolled right;
FIG. 44 is a photographic illustration of the edit display window
in a 3D view mode which is scrolled up;
FIG. 45 is a photographic illustration of the edit display window
in a 3D view mode in which an X-Y coordinate plane is
displayed;
FIG. 46 is a photographic illustration of the edit display window
in a 3D view mode in which a Y-Z coordinate plane is displayed;
FIG. 47 is a photographic illustration of the edit display window
in a 3D view mode in which a Z-X coordinate plane is displayed;
FIG. 48 is a photographic illustration showing a three-dimensional
viewer on which a work is displayed in three dimensions;
FIG. 49 is a photographic illustration of the edit display window
for entering information about a two-dimensional print pattern;
FIG. 50 is a photographic illustration of the edit display window
in which a ZMAP data file is specified;
FIG. 51 is a photographic illustration showing a ZMAP data file
selection window;
FIG. 52 is a photographic illustration of the edit display window
when a ZMAP data file is specified;
FIG. 53 is a photographic illustration of the edit display window
in a 3D view mode in which a work surface is displayed in three
dimensions;
FIG. 54 is a photographic illustration of the edit display window
in a 3D view mode in which three dimensional profile data defined
by the ZMAP data is displayed on a work surface in three
dimensions;
FIG. 55 is a photographic illustration of the edit display window
for editing ZMAP data;
FIG. 56 is a photographic illustration of the edit display window
in which an STL data file is opened;
FIG. 57 is a photographic illustration of the edit display window
in which a representation of three dimensional data is moved in an
X-axis direction;
FIG. 58 is a photographic illustration of the edit display window
in which the representation of three dimensional data is viewed in
a different view point;
FIG. 59 is a photographic illustration of the edit display window
in which a representation of three dimensional data is moved to a
positive side in a Z-axis direction;
FIG. 60 is a photographic illustration of the edit display window
in which a representation of three dimensional data is moved to a
negative side in a Z-axis direction;
FIG. 61 is a photographic illustration of the edit display window
in which a representation of three dimensional data is moved in a
Y-axis direction;
FIG. 62 is a photographic illustration of the edit display window
in which a representation of three dimensional data is rotated
around an X-axis;
FIG. 63 is a photographic illustration of the edit display window
in which a representation of three dimensional data is rotated
around a Y-axis;
FIG. 64 is a photographic illustration of the edit display window
in which a representation of three dimensional data is rotated
around a Z-axis;
FIG. 65 is a photographic illustration of the edit display window
in which boundary representations are displayed to indicate a
printable zone in an X direction;
FIG. 66 is a photographic illustration of the edit display window
in which boundary representations are displayed to indicate a
printable zone in a Y direction;
FIG. 67 is a photographic illustration of the edit display window
in which boundary representations are displayed to indicate a
printable zone in a Z direction;
FIG. 68 is a photographic illustration of the edit display window
in which a representation ZMAP data to which the STL data shown in
FIG. 58 is converted;
FIG. 69 is a photographic illustration of the edit display window
in which a representation ZMAP data to which the STL data shown in
FIG. 62 is converted;
FIG. 70 is a photographic illustration of the edit display window
in which a print pattern is transformed with the ZMAP data;
FIG. 71 is a photographic illustration of the edit display window
in a 3D edit mode in which a unprintable area of a work is
displayed:
FIG. 72 is a photographic illustration of the edit display window
in a 3D edit mode shown in FIG. 71 in which a print pattern
adjusted in print start angle is displayed;
FIG. 73 is a photographic illustration showing printing a laser
parameter setting dialog box;
FIG. 74 is a photographic illustration showing a printable print
block on a work;
FIG. 75 is a photographic illustration showing a user specified
print pattern;
FIG. 76 is a photographic illustration showing a print pattern and
a pattern size;
FIG. 77 is a photographic illustration showing a print pattern
cutting across a defective work surface area;
FIG. 78 is a photographic illustration showing a warning message on
a screen;
FIG. 79 is a photographic illustration showing a guidance message
on a screen; and
FIG. 80 is a perspective illustration showing a method of detecting
a defective processable area by defective area detection means:
FIG. 81 is a photographic illustration showing an environment
configuration window in which a 3D display dialog box is
chosen;
FIG. 82 is a photographic illustration showing an environment
configuration window in which a 3D coloring dialog box is
chosen;
FIG. 83 is a photographic illustration showing an environment
configuration window in which a 2D display dialog box is
chosen;
FIG. 84 is a photographic illustration showing an environment
configuration window in which a 2D coloring dialog box is
chosen;
FIG. 85 is a photographic illustration of the edit display window
in a 3D edit mode shown in FIG. 36 in which a work is changed in
position
FIG. 86 is a flowchart illustrating a sequence of creating a
processing pattern by specifying processing conditions;
FIG. 87A is a perspective illustration explaining two dimensional
printing of a moving work;
FIG. 87B is a plane illustration explaining two dimensional
printing of a moving work;
FIG. 88 is a photographic illustration showing a line setting
window in which movement/direction dialog box is chosen;
FIG. 89 is a photographic illustration of the edit display window
in which a processing parameter setting dialog box is chosen;
FIG. 90A is an illustration showing a processed work section of a
work on which a sloping groove is engraved;
FIG. 90B shows a processed work surface on which a logo is printed
in brushstroke;
FIG. 91 is a photographic illustration of the edit display window
in which a defocus distance setting dialog box is chosen;
FIG. 92 is a table listing items which are selectively specified in
layout adjustment;
FIGS. 93A and 93B are illustrations for demonstrating a correlation
of a Z coordinate to X and Y coordinates with regard to printing a
quadrangular pyramidal work;
FIGS. 94A and 94B are illustrations for demonstrating a tracking
function of a Z-axis scanner;
FIG. 95 is a flowchart illustrating a control sequence of Z-axis
scanner tracking;
FIGS. 96A and 96B are illustrations for demonstrating a tracking
function of a Z-axis scanner while laser irradiation is enabled;
and
FIGS. 97A and 97B are illustrations for demonstrating a tracking
function of a Z-axis scanner while laser irradiation is
disabled.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, embodiments will be concretely described with
reference to the accompanying drawings. Although the following
description is directed to a method of and a system for setting
processing conditions of a laser processing system such as a laser
marker which performs processing such as printing or marking
including characters, symbols and graphics on work with a laser
beam, a computer program for setting processing conditions for a
laser processing system, a computer-readable recording medium or
device on which laser processing conditions are recorded,
nevertheless, the it should be appreciated that the present
invention has broader applications and is not limited to this
particular embodiments.
Further, in the following description, various changes and
modifications may be made in form, size, relative arrangement of
constituent components and means of the described system and
apparatus unless otherwise specified distinctively. It is intended
that all matter contained in the description and as shown in the
accompanying drawings shall be interpreted as illustrative and not
in a limiting sense unless otherwise specified distinctively. The
same or similar components or means of the described system and
apparatus in the accompanying drawings are referred by the same
names and denoted by the same or similar reference numerals. Some
components and means of the described system and apparatus are
illustrated with exaggeration for clear understanding in the
accompanying drawings. Further, some components and means of the
described system and apparatus may be formed in the form of an
integral part, or vice versa.
In the following description, "connection" of the laser processing
system to a computer, a printer, external memory devices and other
peripheral equipments which are used for operating, controlling,
inputting and outputting information or data to and displaying
information or data on the laser processing apparatus is made by
means of electrical communication through wired connection such as
serial connection, parallel connection or a network. Examples of
the serial connection include IEEE1394, RS-232x, RS422, RS423,
RS485, USB, PS2 and the like, examples of the network includes
10BASE-T, 100BASE-TX, 1000BASE-T and the like. The connection is
not limited to wired connection and may be of wireless connection,
including a wireless LAN such as IEEE802, 1.times. and OFDM, and
radio frequency communication, infrared communication or optical
communication such as Bluetooth (trademark). The memory device for
storing data of an object and settings of the system or apparatus
may be any processor-readable medium, including but not limited to
a memory card, a magnetic disk, an optical disk, a magnetic optical
disk, a semiconductor memory, etc. and any combination of two or
more of the foregoing.
Although a laser marker is exemplified as a typical laser
processing system, nevertheless, embodiments of the present
invention are suitable for use on all types of laser-assisted
processing systems or apparatus including laser oscillators, laser
processing devices for boring, marking, trimming, scribing, surface
finishing, light source devices such as a light source for read and
write of high-density optical disk such as DVD and Blue-Ray
(trademark), a light source for a laser printer, an illumination
lit source, a light source for a display equipment, and various
medical equipments. Further, in the following embodiment, the laser
marker is described as used for printing. However, the present
invention is suitable for use on all types of laser-assisted
processing, including fusion or exfoliation of a subject surface,
surface oxidization, surface shaving, discoloring and the like.
As utilized hereinafter, the term "printing" shall mean and refer
to printing or marking of characters, symbols and graphics, and
besides any processing described above.
The term "processing pattern" or "print pattern" as used herein
shall mean and refer to various "characters" such as a variety of
characters and numerical characters, and "symbols" such as signs,
pictograms, icons, logos, barcodes, two-dimensional codes and
combinations of two or more of them, and besides line drawings. In
particular, the term "character" and "symbol" as used herein shall
mean and refer to optically readable characters and symbols.
Examples of the two-dimensional code, stack type or matrix type,
include a QR code, a micro QR code, a data matrix or data code, a
Veri code, an Aztec code, PDF417, a Maxi code, a composite code, an
RSS (Reduced Space Symbology) code such as RSS14, RSS Stacked, RSS
Limited, RSS Expanded, etc. The composite code, which is a
composition of a bar code and a stack type two dimensional code,
may be of any type having EAN/UPC (WAN-13, EAN-8, UPC-A, UPC-E),
EAN/UPC128 or a RSS family (RSS14, RSS Limited, RSS Expanded) as a
base barcode. As additional code may be one of two dimensional
symbols, including MicroPDF417 and PDF417. In the following
example, a combination of a barcode and a micro QR code which is a
two dimensional matrix code is employed.
Referring to the accompanying drawings in detail, and in
particular, to FIG. 1 showing a laser processing system 100 in
accordance with an embodiment of the present invention, the laser
processing system 100 comprises a laser control unit 1, a laser
output unit 2 and an input unit 3. The input unit 3 is connected to
the laser control unit 1, and information necessary to set job
control data of the laser output unit 2 is entered via input unit 3
and sent to the laser control unit 1. The setting information
includes operating conditions of the laser output unit 2, marking
job information such as a print pattern to be printed on a work
surface and the like. The input unit 3 is a console including a
keyboard and a mouse. In order to check up on settings, a display
unit 82 such as an LCD device or a CRT may be provided to display
the setting information entered through the input unit 3 for
checking. A touch panel is available for a terminal device serving
both as an input device and a display.
The laser control unit 1 comprises at least a controller 4, a
memory device 5, a laser excitation unit 6 and a power source 7.
The data of settings are inputted via the input unit 3, sent to the
controller 4 and are stored in a data storage medium of the memory
device 5. The controller 4 reads out data representing the settings
from the data storage medium of the memory device 5 as needed to
drive the laser excitation unit 6 for excitation of a laser medium
8, such as a laser rod, of the laser output unit 2 according to
control signals representing a processing pattern such as a mark or
a text to be printed. The data storage medium may be a built-in
type memory, preferably a semiconductor memory such as RAM or ROM.
The storage medium may be of a removable type such as a
semiconductor memory card including a PC card and a SD card or a
memory card including a hard disc. When the memory device 5
comprises a memory card which can be easily rewritten by an
external equipment such as a computer, data setting is performed
without connecting the input unit 3 to the control unit 1 by
writing the contents set by a computer in the memory card and
placing the memory card in the control unit 1. The laser processing
system 100 is quite easily configured with the memory card placed
in the memory device 5 without keying in data for desired job
control through the input unit 3. Write or rewrite of data in the
memory card can be easily carried out by the use of an external
equipment such as a computer. Typically, a semiconductor memory is
employed because of high data read/write rate, vibration-proof
structure and prevention of data disappearance due to a crush.
The controller 4 provides scan signals for driving a scanner 9 of
the laser output unit 2 through a laser excitation device 6 so as
to scan a work surface with a laser beam L. Specifically, the power
source 7, which is a constant voltage power source, supplies a
specified constant voltage to the laser excitation device 6. The
scan signals for controlling a marking or print job of the laser
output unit 2 comprise pulse width modulation (PWM) signals
corresponding to pulse widths of the laser beam. In this instance,
the intensity of laser beam depends on a duty ratio, or on both a
frequency and a scanning rate, according to a frequency of the
PMW.
As specifically shown in FIG. 4 by way of example, the laser
excitation device 6 comprises a laser excitation light source 10
such as a semiconductor laser or a lamp and a focusing lens system
(schematically depicted by a single lens) 11 fixedly installed in a
casing 12. This casing 12, which is made of a metal having good
thermal condition such as brass, effectively releases heat
generated by the laser excitation light source 10. The laser
excitation light source 10 comprises a laser diode array made up of
a plurality of laser diodes 10a arranged in a straight row. Laser
beams L emanating from the respective laser diodes 10a are focused
on an incident end of an optical fiber cable 13 by the focusing
lens system 11 and exit as an excitation beam from the optical
fiber cable 13. The optical fiber cable 13 is optically connected
to the laser medium 8 directly or through a coupling fiber rod (not
shown).
The laser output unit 2 includes a laser oscillator schematically
shown by reference numeral 50 for exciting the laser medium 8 and
causing it to oscillate to generate a laser beam L in what is
called an end-pumping excitation method, a scanner 9 for scanning a
work surface area three dimensionally which will be described in
detail in connection with FIGS. 5 to 7 later, and a drive circuit
52 for driving the scanner 9. The scanning device 14 comprises
X-axis, Y-axis and Z-axis scanners 14a, 14b and 14c which is built
in a beam expander 53 and an f.theta. lens (not shown). The laser
oscillator 50 comprises, in addition to the laser medium 8, an
output mirror and a total reflection mirror oppositely disposed at
a specified distance, an aperture disposed between these mirrors
and a Q-switching cell, all of which are arranged in a given path
of an induced emission light. The induced emission light from the
laser medium 8 is amplified by multiple reflections between the
output mirror and the total reflection mirror, switched at a short
cycle, selected in mode by the aperture, and then exits as a laser
beam L from the laser oscillator 50 through the output mirror. The
laser oscillator 50 is known in various forms and may take any form
well known in the art. The laser media 8 used in this embodiment is
an Nd:YVO.sub.4 solid state laser rod which has absorption spectra
whose central wavelength is 809 nm. In order to excite the
Nd--YVO.sub.4 solid state laser rod, the laser diodes 10a are
adjusted to emit a laser beam L at a wavelength of 809 nm. Solid
state laser mediums available for the laser medium 8 include a rare
earth-doped YAG, LiSrF, LiCaF, YLF, NAB, KNP, LNP, NYAB, NPP, GGG
and the like. It is practicable to convert a wavelength of the
laser beam from the solid state laser medium by the use of a
wavelength conversion element in combination with the solid state
laser medium. A fiber laser in which a fiber is employed for the
laser medium in place of a bulk may be applied too. Further, the
laser medium 8 is not bounded by a solid state laser medium and it
is practicable to use a gas laser such as a carbon dioxide gas
laser. It is also practicable to exclude the laser medium 8 by the
use of a wavelength conversion element for converting a wavelength
of the laser diode 10a of the laser excitation light source 10.
Available examples of the wavelength conversion element include
KTP(KTiP O.sub.4); organic nonlinear optical media and inorganic
non-linear optical media such as KN(KNbO.sub.3), KAP(KASpO.sub.4),
BBO and LBO; and bulk type polarizing-inverting elements such as
LiNb O.sub.3, PPLN (Periodically Polled Lithium Niobate),
LiTaO.sub.3 and the like. Further, it is allowed to use a laser
excitation semiconductor laser of an up-conversion type using a
fluoride fiber doped with a rare earth such as Ho, Er, Tm, Sm, Nd
and the like.
Referring to FIGS. 5 to 7, the scanning 14 comprises an X-axis
scanner 14a, a Y-axis scanner 14b and a Z-axis scanner 14c built in
a beam expander 53. The beam expander 53 has an optical axis
coaxial with the laser beam L emanating from the laser medium 8.
The X-axis scanner 14c and the Y-axis scanner 14b have scanning
directions perpendicular to each other. The Z-axis scanner 14c has
a scanning direction perpendicular to both scanning directions of
the X-axis scanner 14c and the Y-axis scanner 14b. The X-axis
scanner 14c and the Y-axis scanner 14b scan a working area WS in
two dimensions with the laser beam L emanating from the laser
medium 8. The Z-axis scanner 14c scans the work surface area WS in
an axial direction with the laser beam L by varying a working
distance or focal distance of the laser beam L through the beam
expander 53. In this instance, it goes without saying that the
X-axis, the Y-axis and the Z-axis scanner can function in the same
manner if replaced one another. In FIGS. 5 through 7, an f.theta.
lens, which is a focusing lens system, is not shown.
Because the laser processing system focuses a laser beam L on a
working plane by the use of the second mirror, i.e. the Y-axis
scanner, it is usual to dispose an f.theta. lens between the second
mirror and the working plane so as thereby to make Z-directional
correction. Specifically, the f.theta. lens focuses the laser beam
L always onto a plane work surface. As shown in FIG. 8A, in the
case where the laser beam L L is adjusted to focus on a plane
surface in plane with the work surface WM, as an incident angle of
the laser beam L incident upon the work surface WM becomes smaller,
a focused spot of the laser beam L becomes remote from the work
surface WM as shown by a sign L', resulting in a decrease
processing accuracy. For the grounds, the f.theta. lens is used to
increasingly vary an offset of the focused spot of the laser beam L
from the work surface (i.e. a distance of the focused spot of the
laser beam L from the work surface) according to the incident angle
upon the work surface WM as shown in FIG. 8B. In other words, the
laser beam L is adjusted to focus on a convex surface WM' by the
f.theta. lens so as thereby to keep the focused spot of the laser
beam L on the work surface WM.
In the case where a laser marker is required to focus a laser beam
L with a spot of a diameter less than 50 .mu.m it is preferred to
use such an f.theta. lens. On the other hand, in the case where a
laser marker is required to focus a laser beam L with a spot of a
diameter greater than 50 .mu.m, which is ordinarily about 100
.mu.m, a correction in the Z-direction is performed by the expander
in place of an f.theta. lens. In this way, the f.theta. lens can be
omitted. On the other hand, a spot of a diameter less than 50 .mu.m
the Z-axis scanner is not always sufficiently effective to adjust a
focal point, the use of an f.theta. lens is essential.
The scanning device 14 of this embodiment has three operative
modes, namely a small spot scan mode in which the f.theta. lens is
used, a standard spot scan mode in which the Z-axis scanner is used
in place of the f.theta. lens and a wide spot scan mode in which
Z-axis scanner is used in place the f.theta. lens. In the standard
and wide spot scan modes, the expander of the Z-axis scanner 14c
correctively varies a foal distance so as to keep a focused spot on
the work surface. That is, the offset of focused spot, which is a Z
coordinate, depends unconditionally on X and Y coordinates.
Therefore, the laser spot is always focused on a work surface by
moving the Z-axis scanner so as to adjust a focused spot to a Z
coordinate correlated with X-axis and Y-axis coordinates. The
correlation data is stored in the memory 5A (see FIG. 13A), or
otherwise, may be stored in and transferred from the memory device
5 of the laser control unit 1 of the laser processing system 100.
In this way, since the focused spot of the laser beam L moves in
the Z-axis direction according to movements in the X-axis and the
Y-axis direction, it is enabled to expose a work surface to a
focused spot of the laser beam L uniformly in the working zone
WS.
Each of the scanners 14a, 14b and 14c is made up of a galvanometer
mirror comprising a total reflection mirror and a motor for
rotating a reflective surface about an axis of a rotary shaft of
the motor. The scanners 14a, 4b, 14c are provided with a rotational
position sensor for detecting a rotational position of a rotary
shaft of the motor and providing a signal representing a rotational
position of the rotary shaft. The scanner drive circuit 52 (see
FIG. 1) drives the X-axis, Y-axis and Z-axis scanners 14a, 14b and
14c according to control signals provided by the controller 4 of
the laser control unit 1. For example, the scanner drive circuit 52
controls drive currents to the respective scanners 14a, 14b and 14c
according to control signals provided by the controller 4 of the
laser control unit 1. Further, the scanner drive circuit 52 has a
function of adjusting a time rate of rotational angle of the
scanner with respect to the control signal. This adjustment
function can be embodied by a semiconductor element such as a
variable resistor operative to change parameters for the scanner
drive circuit 52.
Referring to FIGS. 9 to 11, the Z-axis scanner 14c is accompanied
by the beam expander 53 which varies a focal length so as to adjust
a spot size of the laser beam L on a given work surface area as
small as possible. The expander 53, which comprises two lenses or
lens groups at incident and exit sides, respectively, varies its
focal length by changing a relative axial distance between the two
lenses. In other words, the beam expander 53 varies a focal
distance (which is hereinafter referred to as a working distance in
some cases) at which a minimum size of the beam spot of laser beam
L is formed on a given work surface. In order to effectively vary
the focal distance, the beam expander 53 is disposed before the
galvanometer mirror of the Z-axis scanner 14c as shown in FIG. 5.
In order to provide a more specific explanation, reference is made
to FIGS. 9 to 11. As shown, the Z-axis scanner 14c includes a
variable-focal length lens system comprising a movable lens or lens
group 16 at an incident side and a stationary lens or lens group 18
at an exit side. The movable lens 16 is axially moved back and
forth by a driving mechanism including a galvanometer (not shown).
The drive mechanism includes a movable element for holding the lens
16 and a coil and magnet assembly for causing axial movement of the
movable element. As shown in FIG. 9, when bringing the lenses 16
and 18 close to each other, the variable-focal length lens system
changes its focal length to longer, so as hereby to make a working
distance longer. On the other hand, as shown in FIG. 10, when
bringing the lenses 16 and 18 far away from each other, the
variable-focal length lens system changes its focal length to
shorter, so as hereby to make a working distance shorter. In this
instance, the stationary lens and the movable lens may be replaced
with each other or may be both movable. The three-dimensional laser
processing system, which is capable of processing in a direction of
work height, besides in length and breadth, may employ a manner of
moving a focusing lens or a manner of moving a laser output unit or
a laser processing head itself, instead of the Z-axis scanner
adjustment. Although the lenses 16 and 18 are movable relatively to
each other to vary its focal length, either one of the two lenses
16 and 18 may be fixedly disposed in the path of the laser beam
L.
The laser scanner 14 shown in FIGS. 5 and 6 is provided with a
distance pointer. As shown in FIGS. 5 and 6, the laser scanner 14
is provided with a distance pointer which comprises optical axis
alignment means comprising a light source 60 for producing a guide
beam G and an adjustable beam guide element 62 in the form of a
reflective mirror and distance pointing means comprising a light
source 64 for producing a pointing beam P and a pointer scanner 4d
in the form of a reflective mirror formed on the back of the Y-axis
scanner 14b and a stationary mirror 66 for reflecting the pointing
beam P toward a scanning area. The beam guide element 62 is
adjusted so as to bring the guide beam G into alignment with an
optical axis of the laser scanner 14. The distance pointer projects
a spot of the pointing beam P on a line along the guide bam G for
indicating a focal point at which a scan laser beam should
focus.
Although, in the above embodiment, the laser scanner 14 is enabled
to perform three-dimensional processing by the use of a focal
length or distance adjusting mechanism, it may be permitted to move
a work table up and down so as to put a work surface on the work
table in a focal plane in which the laser beam is focused.
Similarly, the laser scanner may be replaced with a mechanism for
moving the work table in X-direction and/or Y-direction. This
alteration is suitable for laser processing devices for use with a
work table in place of a belt conveyer system.
FIG. 12 shows a three-dimensional laser marking system as a laser
processing apparatus according to an embodiment. The laser marking
system comprises at last a laser marking head 150 as a laser output
unit, a control unit 1A connected to and controlling the laser
marking head 150, and a laser processing data setting system 180
connected to the control unit 1A for data communication with the
control unit 1A through which three-dimensional laser processing
data representing a print pattern is set to the laser control
system 180. In this embodiment, the laser processing data setting
system 180 comprises a computer on which a three-dimensional laser
processing data setting program is installed. The laser processing
data setting system 180 may be comprised by a programmable logic
controller (PLC) equipped with a touch panel or other specialized
hardware, as well as computer. The laser processing data setting
system 180 may be used as an integrated controller for performing
the function of laser processing data setting and the function of
operation control of a laser processing device such as the laser
marking head. Furthermore, the laser processing data setting system
180 may be provided separately from the laser processing device or
may be integrated as a single means with the laser processing
device. For example, the laser processing data setting system 180
may be provided in the form of a laser processing data setting
circuit incorporated into the laser processing device.
The control unit 1A is further connected to external equipments
such as a programmable logic controller (PLC) 190a, a distance
measuring device 190b and an image recognition device 190c, as well
as a photo diode (PD) sensor and other sensors (not shown). The
programmable logic controller (PLC) 190a controls the system
according to a given sequence logic. The image recognition device
190c, which may comprise an image sensor, detects attributes such
as type, position and the like of a work conveyed in a processing
line. The distance measuring device 190b, which may be a
displacement pickup 190b, acquires information about a distance
between a work and the marking head 150. This external equipment is
connected to the control unit 1A for data communication.
Referring to FIG. 13A illustrating the architecture of the marking
data setting system 180 for setting laser marking or printing data
to perform printing of a planar print pattern in three dimensions
as an example of the laser processing apparatus, the laser
processing data setting system 180 comprises an input unit 3
through which information about an intended three-dimensional
printing job is entered, an arithmetical and logic unit 80 for
generating laser processing or printing data based the information
entered through the input unit 3, a display unit 82 for displaying
a representation of the generated laser printing data, and a memory
device 5A for storing the laser printing data. The memory device 5A
has a reference table 5a maintaining a plurality of combinations of
processing parameters which are correlated with one another. The
display unit 82 includes an object display section 83 for
displaying a work surface of an object in three dimensions and a
head display section 84 for displaying a laser marking head when
displaying a work surface of an object on the object display
section 83. The input unit 3 includes a processing condition
setting means 3C for inputting printing conditions necessary to
perform given printing in a desired pattern. Specifically, the
processing condition setting means 3C performs the function of
inputting information about a profile of three-dimensional work
surface via work surface profile input means 3A, the function of
inputting information about a process pattern such as a print
pattern via processing pattern input means 3B, the function of
creating a process block of a plurality of process patterns for
block processing via process block generating means 3F, the
function of grouping the blocks established by the process block
generating means 3F via process block grouping means 3J, and the
function of adjusting a position of a processing pattern on a work
surface via position adjusting means 3K. Furthermore, the work
surface profile input means 3A performs the functions of
selectively specifying elemental profiles via elemental profile
specifying means 3a and the function of importing information about
three dimensional data representing a profile of a work surface
from an external equipment via 3D data input means 3b. The memory
section 5A, which corresponds to the memory device 5 shown in FIG.
1 and stores data representing the information about a profile of
three-dimensional work surface, a given process or print pattern,
processing patterns and the like inputted through the input unit 3,
may comprise a semiconductor memory, as well as a storage medium
such as a fixed storage device. The display unit 82 may be
exclusively provided for the three-dimensional laser processing
system or may be a monitor of a computer connected to the
three-dimensional laser processing system.
The arithmetical and logic unit 80, which comprises a large-scale
integrated circuit or an integrated circuit for data processing,
has a processing data generation means 80K for generating actual
processing data, an initial position setting means 80L for
determining an initial end position on a work surface to which a
representation of three dimensional processing data is justified on
the display unit 82, a defective surface area detection means 80B
for detecting a defective work surface area which is only
defectively processable or unprocessable by performing
calculations, a highlighting means 80I for displaying a work
surface with a defective work surface areas highlighted differently
from a processable work surface area, and a warning means 80J for
providing a warning that a processing pattern is seized with a
defective work surface area even pertly when setting the processing
pattern through the processing condition setting means 3C. If
necessary, the arithmetical and logic unit 80 may have a processing
condition adjusting means 80C for adjusting processing conditions
so as to enable laser processing to be applied to the defective
work surface area and coordinate conversion means for converting
information about a plane processing pattern into special
three-dimensional special coordinate data so as to make the
processing pattern virtually fit a three-dimensional work
surface.
Although, in FIG. 13A, the laser processing data setting system 180
is made up by dedicated hardware, however, laser processing data
setting may be performed by the use of software. In particular, as
shown in FIG. 12, a general purpose computer with a laser
processing data setting program installed therein may be used.
Furthermore, although the laser processing data setting system 180
and the laser processing apparatus 100 are separately provided,
they may be integrated as one unit. The processing data generation
means 80K is incorporated in the laser processing data setting
system 180. That is, the function of the processing data generation
means 80K is realized by a general-purpose computer with the laser
processing data setting program installed therein which is used as
the laser processing data setting system 180. However, as shown in
FIG. 13B, processing data generation means 180K may be incorporated
in the control unit 1A of the laser processing system 100 in
addition to the processing data generation means 80K of the laser
processing data setting system 180. This functional feature allows
both of the laser processing data setting system 180 and the laser
processing system 100 to individually generate laser processing
data and to transfer, edit and display the laser processing data,
respectively. In the embodiment shown in FIG. 13B, the processing
data generation means 180K of the laser processing system 100
generates laser processing data and transfer it to the processing
data generating means 80K of the laser processing data setting
system 180 and the display unit 82. Furthermore, as shown in FIG.
13C, it is, of course, practicable to provide only the processing
data generation means 180K incorporated in the control unit 1A of
the laser processing system 100.
The following description is directed to a sequence of generating a
print pattern from character information inputted through the
processing condition setting means 3C by means of execution of a
laser processing data setting program. In making explanation to the
sequence, reference is made to FIGS. 14 and 15 illustrating a user
interface window by way of example. In the individual user
interface windows, a layout of dialog boxes, buttons, tab keys and
the like of the user interface window may be appropriately changed
in location, shape, size, color, pattern and/or the like. The
layout of elements of the window may be changed so as to be
suitable for clear view, easy assessment and easy judgment. For
example, it is not prevented to use a separate window for details
setting and/or to open a plurality of windows or dialog boxes
incidentally. Operation of buttons and dialog boxes, selection of
commands and numerals in boxes are made through the input unit 3
connected to a computer in which the laser processing data setting
program is installed. In the following description, the term "press
a button" includes pressing a button on physically direct contact
with it, or clicking a button through the input unit. The
input/output device forming the input unit 3 may be unified with
the computer, as well as connected to the computer through wireless
communication or cable communication. The input/output device may
be any commercially available pointing device, including a mouse, a
keyboard, a slide pad, a track point, a tablet, a joystick, a
console, a jog dial, a digitizer, a light pen, a ten-key keyboard,
a touch pad, etc. and may be used not only for management of the
program, but also for operation of the hardware of the laser
processing apparatus. Furthermore, it can be made to display a user
interface window on a touch screen or a touch panel used as a
screen of the display unit 82 so as to enable users to touch the
window physically with a finger for buttons operation. It can also
be made to use a voice input device or other existing devices,
individually or in combination.
The laser processing data setting program is designed to edit
three-dimensional laser processing data. However, in consideration
of users who are unfamiliar with three-dimensional data editing,
the laser processing data setting program may be designed to run in
two edit modes, namely a two-dimensional edit mode (2D edit mode)
and a three-dimensional edit mode (3D edit mode). The 2D edit mode,
which is a fool-proof default mode on startup of the laser
processing data setting program, prevents users not good at 3D data
editing from being confused. In this case, as shown for example in
FIGS. 14 and 15, a current mode indicator 2D or 3D appear
alternately in a current mode indication box 270 by pressing an
edit mode switch button 272. It is practicable to configure the
laser processing data setting program so that a default edit mode
is selectively switched between 2D and 3D edit modes. This
configuration makes it easy for advanced users to select the 3D
edit mode automatically on startup of the laser processing data
setting program. On the other hand, the edit mode switch button 272
is marked with 3D meaning that a current window is changeable to
the 3D edit mode when the current window is in the 2D edit mode or
2D meaning that a current window is changeable to the 2D edit mode
when the current window is in the 3D edit mode. According to the 2D
edit mode which limits or excludes 3D display and 3D editing of an
object, the edit and display window allows users to set and edit
two-dimensional processing data only, so that the edit and display
window is simplified and provides improved operationality. The 2D
edit mode allows users to carry out preliminary editing of
two-dimensional processing data on the edit display window in the
3D edit mode, not directly on the 3D edit display mode which
regular users are unaccustomed to, and subsequently to reedit the
two-dimensional processing data on the edit display window in the
3D edit mode so as thereby to achieve three-dimensional processing
data. In this way, the edit display window facilities operation and
provides improved operationality.
The edit display windows in the 2D edit mode and the 3D edit mode
window shown in FIGS. 14 and 15, respectively, have almost similar
appearances. When the 2D edit mode window appears, a 3D Setting tab
204i for setting a three-dimensional profile grays out and is
disabled. The 3D Setting tab 204i is enabled upon a switch from the
2D edit mode window (FIG. 14) to the 3D edit mode window (FIG. 15).
In this way, the user interface window is switched smoothly from
the 2D edit mode o the 3D edit mode, and vice versa, by putting
restrictions on settable items but without accompanying significant
alterations in appearance.
As just described above, since the user interface window is almost
the same in the 2D edit mode and the 3D edit mode,
three-dimensional laser processing data can be set up and edited in
the same knack as the two-dimensional laser processing data. In
three-dimensional laser processing data setting, a character size
and a profile of a print pattern are specified in the 3D mode user
interface window the same as the 2D mode user interface window.
Subsequently, information about three-dimensional profile is
combined with the settings of the two-dimensional profile in order
to provide three-dimensional laser processing data. In this
instance, the user can set actual print data while seeing a
full-frontal two-dimensional representation of the laser processing
data as viewed on a side of the laser processing head and a
three-dimensional representation of the processing data as viewed
in any specific direction which are alternately hanged. The user
interface windows enables users experienced only in two-dimensional
laser processing data setting and editing to set up and edit
three-dimensional laser processing data in a simple way.
Explaining elements forming the processing condition setting means
3C of the user interface window with reference to FIGS. 14 and 15,
the user interface window includes an edit display window 202 at
the left-hand side thereof and a Print Pattern input dialog box 204
at the right-hand side thereof. The edit display window 202
displays editing print pattern data. The Print Pattern input dialog
box 204 includes various buttons, tab keys and areas for specifying
printing conditions. Specifically, there are provided in the window
setting items selection tabs, including a Basic Setting tab 204h,
the 3D Setting tab 204i and a Details Setting tab 204j, which are
selectively enabled. In the Print Pattern input dialog box 204
shown in FIG. 14, the Basic Setting tab 204h is enabled by default,
and the remaining tabs 204i and 204j are hidden. There are further
provided in the Print Pattern input dialog box 204 several menus
boxes and boxes, namely a Print Category select box 204a, a Text
box 204b, a Details input dialog box 204c and a Print Type menu box
204q. In the Print Type menu 204a, a print category which the user
wants to specify is selected from a pull-down menu including
Character String, Symbol.Logo and Printer Operation. In FIG. 14,
Character String is selected by default. In the Character Data menu
box 204d, a print type which a user wants to specify is selected
from a pull-down menu including Character, Barcode, 2D Code and
RSS.CC (Reduced Space Symbology.Composite Code). In the Type menu
box 204q, a particular type is specified from a pull-down menu
according to the selected print category. The type menu shows
various font types when Character is selected; CODE39, ITF, 2 of 5,
NW7, JAN, Code 28 and the like when Barcode is selected; QR code, a
micro QR code, Data Matrix and the like for the 2D code; and
RSS-14, CC-A, RSS Stacked, RSS Stacked CCA, RSS Limited, RSS
Limited CC-A and the like when RSS.CC is selected. In the Text box
204b, characters which the user wants are typed in. When Character
is selected as a print type in the Character Data menu box 204d,
the typed in characters are printed in a string as they are. On the
other hand, when Symbol is selected as a print type in the
Character Data menu box 204d, the typed characters are encoded in
print pattern according to a selected type of symbol. The print
pattern is generated in the processing condition setting means 3C,
or otherwise may be generated in the processing data generation
means 80K of the arithmetical and logic unit 80. In Details input
dialog box 204c, there are provided three tabs, namely Print Data
tab 204e, Size-Position tab 204f and Printing conditions tub 402g,
for specifying details of printing conditions. In the 2D mode edit
display window 202 shown in FIG. 14, a QR code is selected in the
Character Data menu box 204d, and, correspondingly, a cell size, a
line thickness of character, a percentage of error correction and a
version number are quantified. There are further provided check
boxes for selection of Auto Mode, Reverse and Password.
When selecting Printer Operation in the Print Category menu box
204a, it is enabled to select an print style in a pull-down
operation menu including Fixed Point, Straight Line, Broken Line,
Clockwise Circle/Ellipse, Counterclockwise Circle/Ellipse, Centered
Point and the like. In the Printer Operation category, Details
setting box 278c appears in place of the Details input dialog box
204c for specifying a locus of line, such as a straight line, a
circular arc or the like, in coordinates as shown. For example,
FIG. 16 shows the edit display window 202 in which Broken Line is
selected. FIG. 17 shows the edit display window 202 in which
Clockwise Circle/Ellipse is selected. FIG. 18 shows the edit
display window 202 in 3D edit mode in which a line is displayed in
three dimensions.
The laser processing system is not applied only to character
printing but to printing of image data representing symbols such as
logos and graphics shown in FIGS. 19 and 20. Specifically, when
choosing "Logo-Graphics" in a Category menu box 204a, a print
pattern dialog tab 217 and a print condition setting tab 218
appear. In the print pattern dialog tab 217 shown in FIG. 19, the
user specifies an external file name to be imported and details of
a selected print pattern. It is convenient to previously provide
external files of logos and graphics in the form of raster image
data or vector graphics data. Further, in the print condition
setting tab 218 shown in FIG. 20, the user specifies details of
printing conditions.
In this way, print pattern data regarding a print block is
established. A plurality of print blocks may be provided. That is,
a work surface area or print area is divided into a plurality print
blocks for printings under different printing conditions,
respectively. It can be made to set a plurality of print blocks on
a single work and, at the same time, one print block on each of a
plurality of works within the work surface area. As shown in FIGS.
14 and 15, setting of a print block is made by block setting means
such as a Block Number spin box 216 with Number Change buttons
which are located above the Print Pattern input dialog box 204,
namely an Increment button marked with ">", a Decrement button
marked with "<", a Maximize button marked with ">>" and a
Minimize button marked with "<<" for changing a block number.
In order to specify a block number in the Block Number spin box
216, the Increment button or the Decrement button is pressed to
change a block number by one increment or one decrement,
respectively. When pressing the Maximize button or the Minimize
button, the current block number in the Block Number spin box 216
jumps to a minimum block number, e.g. 0 in this embodiment or to a
maximum block number, e.g. 255 in this embodiment, respectively.
Otherwise, it can be made to specify a block number by entering a
desired block number in the Block Number spin box 216. The edit
display window 202 shown in FIG. 14 displays a QR code by
specifying a block number of 000. The edit display window 202 shown
in FIG. 15 is provided with three print blocks set therein in which
a QR code, a barcode and a character string are displayed by
specifying block numbers of 000, 001 and 002, respectively. When
enabling the Print Data tab 204e, the print data dialog panel
appears for specifying a height of barcode, a narrow space width,
bar thickness, a thickness ratio of fine and heavy bars and the
like. As appropriate, Check Digit and Reverse can be specified. A
layout of print blocks can be desirably changed by adjustment of
locations of the print blocks (centering of print blocks, right and
left justification of print blocks, even distribution of print
blocks), superposition ordering of print blocks and positioning of
print blocks. For example, FIG. 21 shows three print blocks which
are justified centrally in a transverse direction and distributed
evenly in a vertical direction in the edit display window 202. It
can be made to position a print block by coordinates. For example,
FIG. 21 shows a character string specified by a block number
specified by typing X and Y coordinates in numerical value in Size
Position boxes of a Size-Position panel which appears when the
Size-Position tab 204f is enabled. The Size Position panel includes
buttons for specifying a character format including a character
height, a character width, a character spacing and the like. It can
be also made to specify writing directions and inner and outer
diameters of a column when printing a three-dimensional columnar
work surface.
FIG. 22 shows a block list window. This block list window appears
when selecting an Edit command in the menu bar (see FIG. 15) to
display a pull-down menu and then selecting Block List in the menu.
In the block list, reset of a specified print block, deletion of
specified print block, addition of a new print block can be made.
It can be made to execute a batch transformation of profiles of
print blocks. In the case where the user wants to make a
transformation of three print blocks comprising two circular cones
and one sphere such as shown in FIG. 23 by way of example into
three columnar print blocks, when pressing a button 274 for 3D
Profile Batch Transformation which is located at the bottom of a
tool bar at a left side of the edit display window 202, a 3D
Profile Batch Transformation window 275 appears as shown in FIG.
24. The 3D Profile Batch Transformation window 275 includes a
current print block list which describes individual print blocks
together with a block number, position coordinates, a graphic type
and a character string. After choosing any of the print blocks
which the user wants to transform by checking a check box of the
print block, a profile into which the user wants to transform the
selected print block is selected from a pull-down menu of a Profile
menu box 276 including a plane, a column, a sphere, a circular
cone, 3D processing machine, ZMAP, etc. When the user wants to
transform all of the print blocks into a specific profile
collectively, after choosing Bach Transforming Block Profiles check
box 277, the user specifies details of the profile in the dialog
box. Regarding the example shown in FIG. 24, the user chooses a
column as a profile to which the user wants to transform the
selected print block, in the Profile menu box 276, and, thereafter,
specifies a diameter and a print surface in a Diameter spin box and
a Print Side menu box in the Block Profile Bach Transformation
dialog box. When an OK button is pressed, an edit display window
202 appears to display three columnar print blocks having the same
diameters all together as shown in FIG. 71. This batch
transformation function facilitates easy operation and is
laborsaving in print block transformation.
FIGS. 26 to 34 illustrate a function of grouping a plurality of
print blocks into one print group in order to set up printing
conditions such as laser power and scan speed by group. FIGS. 26
and 27 show edit display windows 202 in which a plurality of print
blocks generated through the print block generating means 3F are
displayed in two and three dimensions, respectively. In this
instance, one print block allows a single line of print only.
Therefore, when it is requested to print two or more lines in one
print block, a plurality of print blocks are established side by
side as they are in one unified print block. As shown in FIGS. 26
and 27, a columnar print block of a character string "abcde" (print
block B1 which is identified by a block number 000) and a columnar
print block of a character string "ABCDE" (print block B2 which is
identified by a block number 001) are established on a columnar
work surface and set up vertically side by side. Printing
conditions are specified for the individual print blocks B1 and B2.
In the past, users were required to specify printing conditions by
print block. In such a case, since the print blocks B1 and B2 are
applied to a single work, many printing conditions are often common
to both print blocks B1 and B2. If specifying the same printing
conditions by print block in the conventional way, the printing
condition specifying operation is somewhat troublesome. In
particular, in the case where a large number of print blocks are
established, the same printing conditions have to be entered over
and over again. This is a time consuming operation. In order to
avoid this problem, the processing block grouping means 3J is used
to group a plurality of print blocks into one print group so as
thereby to enable users to specify printing conditions by print
group.
As shown in FIG. 28, after choosing a Print Block Grouping check
box in the Grouping dialog box 250 and selecting a print block
which the user wants to group by its print block number, a group
number is specified in Group Number spin box 252. Selection of a
print block which is required to be grouped is achieved by defining
a work surface area including the print block in the edit display
window 202 using a pointing device such as a mouse pointer as shown
in FIG. 29 and then pressing Group button 253. After defining the
work surface area, or otherwise pointing a plurality of print
blocks which the user wants to group with a mouse pointer, the user
presses a right mouse button to call a pop-up menu 256. As shown in
FIG. 30, when selecting Grouping in the pop-up menu 256, a
pull-down menu 257 listing Grouping, Ungrouping and Regrouping
appears. Then, the Grouping is selected in the pull-down menu 257.
Every time several print blocks are grouped, a group number is
automatically assigned to groups from 000 in order of grouping. In
this embodiment, grouping is permitted up to 245 groups. This
grouping function enables users to specify printing conditions
collectively by group. In an example shown in FIG. 59, print blocks
B1 and B2 are pointed to be grouped as a group G1 in the edit
display window 202 in the 2D edit mode and a group number (000 in
this example) is assigned to the group by specifying a number in a
Grouping dialog box 250 of the Print Pattern input dialog box 204.
As a result, a print group frame or box GW appears to indicate an
area of the print block group G1 which encloses double character
strings which are grouped. As shown in FIGS. 30 and 31, the frame
or box may be changed from a print block frame or box BW enclosing
a singe print block to a print group frame or box GW enclosing
grouped print blocks. In this way, two character strings "abcde"
and "ABCDE" are handled as though they are one. The image of frame
or box may be identical or may be different in appearance between
the print block frame or box and the print group frame or box. When
displaying the print block frame or box BW by a fine line and the
print group frame or box GW by a bold line, these print block frame
or box BW and print group frame or box GW are sharply distinctive.
Furthermore, these frames or boxes may be differed by line styles
such as solid line and broken line, line colors, or the like. It is
desirable to achieve the grouping operation in the edit display
window 202 in the 2D edit mode as shown in FIG. 28 since the 2D
representation of a print block is simple and easy in selection.
However, it is practicable to achieve the grouping operation in the
edit display window 202 in the 3D edit mode as shown in FIG.
29.
The grouping function is effective not only to group print blocks
or print groups adjacent one another but to group print blocks or
print groups spaced from one another. As shown in FIG. 33 showing
the case where three groups each of which comprises double
character strings "abcde" and "ABCDE" are printed on a surface of a
can, three print blocks of character string "abcde" B3, B4 and B5
are grouped into one group G2, and three print blocks of character
string "ABCDE" B6, B7 and B8 are grouped into one group G3. This
grouping enables to specify print density differently between the
character strings "abcde" and "ABCDE". In this way, print blocks
can be grouped by printing condition, as well as by print pattern
such as characters, logos or the like. FIG. 34 illustrates the case
where a plurality of print blocks are grouped into different groups
for two or more works. Specifically, as shown, different print
patterns are printed on works W1, W2 and W3, and a group of double
character strings "abcde" and "ABCDE" is printed on the work W1.
The works W2 and W3 may be printed in identical print patterns and
under the same conditions. Accordingly, a plurality of works and a
plurality of print blocks can be grouped together in any
combination. The grouped print blocks or print groups can be
ungrouped by pressing Ungroup button 254 in the Grouping dialog box
250 shown in FIG. 59 or selecting the ungroup function in the
pull-down menu 257 as shown in FIG. 61. The ungroup function is
convenient in such a case where the user wants to ungroup one or
more print blocks grouped in one in order to be specified
differently in printing condition from the remaining print
blocks.
Referring back to FIG. 14, plane work surface profiling is possibly
performed through the work surface profile input means 3A (see FIG.
13A) in the following ways.
(1) A Method of Drawing a Three-Dimensional Work by the Use of a 3D
Graphic Design Program.
This method uses drawing tools such as a line tool, a curve tool,
box tool, etc. functionally similar to existing three-dimensional
CAD software, three-dimensional modeling software and drawing
software in order to create a three-dimensional graphic image. This
method is casually used by users skilled in the task of
three-dimensional graphics drawing but is difficult to understand
and/or for users who are unfamiliar with three-dimensional data
editing.
(2) A Method of Defining a Three-Dimensional Work Surface Profile
by Specifying Geometric Parameters in the Form of a Dialog.
This method uses wizard software to define a three-dimensional
graphic image through an interactive dialog. This method is
casually used because no knowledge and experience of
three-dimensional graphics drawing is required. For example, the
method is in need of specifying an elemental profile for a work
profile and parameters for defining the profile only. Specifically,
a user is required only to select a desired work profile from an
option menu and to specify parameters for the selected work
profile. Necessary parameters to be specified by the user are
position coordinates of a control point and a direction of a normal
vector when an oblique plane is selected, position coordinates of a
control point, an outer diameter and a direction of a center axis
when a column is selected, and position coordinates of a center and
a diameter when a sphere is selected.
(3) A Method of Choosing an Elemental Profile and Specifying
Parameters of the Elemental Profile.
Not limited to interactive modes, a pseudo profiling method which
represents a work surface by an elemental profile is available.
That is, users are requested to selectively specify prepared
elemental profiles such as a column-shaped profile, a cone-shaped
profile, a sphere-shaped profile and the like, and subsequently to
specify numeric values of parameters defining the selected profile.
In this way, a work surface profile is easily altered from a 2D
representation to a 3D representation. This pseudo profiling method
facilitates specifying operation of a three-dimensional profile of
a work surface.
(4) A Method of Importing a 3D Data File Prepared for a Work
Surface Profile and Converting it.
This method uses a 3D data file of a work surface provided
separately by a 3D CAD program and converts it into a 2D data file.
Because 3D data files previously provided are available, this
method saves a user a lot of labor. In this instance, readable data
file formats include various generalized file formats such as a DXF
format, an IGES format, an STEP format, an STL format, a GKS format
and the like. Furthermore, a format exclusive to an application
such as a DGW format may be used for 3D data file conversion.
(5) A Method of Defining a Height Directly in Two Dimensional
Data.
This method involves numerical data about a height and an
inclination in the direction of height in two dimensional data
representing a print pattern. In an example shown in FIGS. 35 and
36 in which a print block B9 comprising a character string
"ABCDEFGHIJKLM" is printed on an inclined work surface, after
choosing a Basic Setting tab and then specifying Basic Profile in
the Category menu box in the Print Pattern input dialog box 204, a
plane is specified in a Type menu box to display a plane work
surface in two dimensions in the edit display window 202 as shown
in FIG. 35. While displaying a print block B1 in two dimensions in
the edit display window 202, a Layout tab 216 is opened to specify
X-axis and Y-axis offsets in X and Y offset boxes, respectively.
Thereafter, a Block Profile Layout tab 211 is opened to specify
angles of rotation in X-, Y, and Z rotational angle boxes 211B to
display a layout of the as shown in FIG. 36. An angle of rotation
can be specified by choosing a value in a spin box by a scroll
arrow or a scroll slide. In FIG. 36, the print block B1 is
displayed when specifying an angle of rotation in the X-axis. This
method is, on one hand, advantageous to a representation of a
simply stepped profile or an inclined profile and, on the other
hand, not adequate to a representation of a complicated
profile.
(6) A Method of Importing an Actual Image of a Work Surface Through
an Image Recognition Device Such as an Image Sensor.
This method automatically acquires data by importing an image of a
work surface through an image sensor or the like.
In this embodiment, the methods (3) and (4) are employed in this
embodiment.
Referring to FIGS. 37 to 39 showing the method (3), there are
provided means for selecting a profile from prepared elemental
graphics and means for reading a data file of 3D profile. When
enabling the Profile Setting tab 204i in the Print Pattern input
dialog box 204 (see FIG. 14), the edit display window shows a
profile menu box including Elemental Graphic, ZMAP and Machine
Operation as shown in FIG. 37. The Elemental Profile is selected by
default. When the Elemental Profile is selected, a pop-up menu 206
appears to list types of elemental graphics such as a plane, a
column, a sphere, a cone, etc. which are highlighted by selection.
Plane is selected by default and highlighted in the Profile menu
box 206. When selecting Column as shown in FIG. 38, the edit
display windows 202 changes an object from plane-shaped to
column-shaped. That is, a QR code to be printed on a columnar work
surface is displayed in a plane with X-Y coordinate system. As a
consequence, the displayed QR code diminishes in width as closing
to the right end. When the user wants to display an object or work
surface in three dimensions, the edit display window 202 is altered
from a 2D view mode to the 3D view mode shown in FIG. 38 by
pressing a View button 207A, thereby displaying a work surface in
three dimensions. The edit display window 202 in the 3D view mode
shown in FIG. 39 is altered back to the edit display window 202 in
the 2D edit mode shown in FIG. 38 by pressing the View button 207A.
In this way, the edit display window 202 is alternately changed
between the 2D view mode and the 3D view mode. An icon on the View
button 207A is altered between an indication of "2D" and an
indication of "3D" correspondingly to a switch of the edit splay
window 202 between the 2D view mode and the 3D view mode. The print
pattern, i.e. the QR code, is enclosed in a frame or box K in the
edit splay window 202 in the 3D view mode shown in FIG. 39
similarly in the 2D view mode shown in FIG. 38. The tool bar 207
including the View button 207A is in the form of a floating tool
bar which can be freely shifted within the window, it may be hidden
as appropriate, or otherwise, may be incorporated in an ordinary
fixed tool bar.
FIGS. 40 to 47 show the edit display windows 202 which display an
object or work as though the user views it at different view points
in the edit display window 202 in the 3D edit mode. Explaining the
view point shift function taking a QR code shown in FIG. 38 for
example, when pressing the View button (View mode switch button)
207A of the floating tool bar 207 in the edit display window 202 in
the 3D edit mode shown in FIG. 38, the edit display window 202 in
the 3D edit mode appears as shown in FIG. 39. The view point is
shifted at will as shown in FIGS. 40 through 47 by moving a scroll
bars 209 up or down and right or left in the edit display window
202 in the 3D view mode shown in FIG. 38. FIG. 40 shows the edit
display window 202 in which the work with a QR code is viewed
obliquely from above. FIG. 41 shows the edit display window 202 in
which the object or content is rotated by 180.degree. and viewed
from behind. The view point may be otherwise shifted by dragging
any point of the edit display window 202. When pressing a
Move/Rotation button of the tool bar 207, the scroll bars 209 are
altered from a rotation function to a move function. In this state,
when moving the scroll bar 209 up and down or right and left, a
viewing field including an object moves up and down or right and
left correspondingly in the edit display window 202 as shown in
FIGS. 42 and 43. In this way, the scroll bars which are altered
between an object rotating function and an object moving function
by the Move/Rotation button of the tool bar 207 facilitates
operation to change a viewing field, and hence a view point. As a
consequence, even users who are unfamiliar with three-dimensional
graphic editing are enabled to easily shift a view point.
Further, as shown in FIGS. 45 to 47 showing the edit display window
202 which displays an object or work in the 3D display mode as
though the user views it at different fixed view points, the fixed
view point is changed by pressing a Display Position button 207B of
the tool bar 207. Specifically, when pressing the Display Position
button 207B in the edit display window 202 shown in FIG. 45 which
corresponds to the edit display window 202 shown in FIG. 38 and in
which a view point is fixed above an X-Y coordinate plane, the edit
display window 202 changes to display a Y-Z coordinate plane as
though a view point is above the Y-Z coordinate plane as shown in
FIG. 46. When pressing the Display Position button 207B in the edit
display window 202 shown in FIG. 46, the edit display window 202
changes to display a Z-X coordinate plane as though a view point is
above the Z-X coordinate plane as shown in FIG. 47. In this way,
the quick cyclical change of a viewing plane in the 3D view mode is
advantageous to a changing a fixed view point.
In the above embodiment, the edit display window 202 is switched
over from the 2D edit mode to the 3D edit mode, and vice versa. In
case where it is desired to display same objects (same work
surface) in both two dimensions and three dimensions, respectively,
the laser processing data setting program provides a 3D viewer
window 260. When selecting a 3D Viewer Open button 207C in the
floating tool bar 207 in the edit display window 202 in the 2D edit
mode, a 3D viewer window 260 appears over the edit display window
202 as shown in FIG. 48. The 3D viewer window 260 can be moved to
any desired location on the screen by dragging its title bar or any
portion thereof and changed in size. A work can be changed in
position, rotated and scaled as desired. Since it is not required
to open the 3D viewer window 260 while the edit display window 202
is in the 3D edit mode as shown in FIG. 39, the 3D Viewer Open
button 207C in the floating tool bar 207 grays out and is disabled
to prevent erroneous operation. It is also possible to display a 2D
viewer window separately from the edit display window 202. The 3D
viewer window 260 may be changed in layout, size and position as
desired. In this way, the edit display window 202 and the 3D viewer
window 260 are used for the object display section 83 of the
display unit 82. The 3D viewer 260 appears with a grid and scales
for facilitating easy grasp of a view point. The grid and scales
may be hidden as appropriate.
FIGS. 49 to 54 show a method of importing a 3D data file prepared
for a work surface profile which has been prepared by the use of,
for example, a 3D CAD and converting it. This method basically
pastes a two dimensional print pattern data to three dimensional
profile data. The term "ZMAP" file as used hereinafter shall means
and refer to a three dimensional profile data file in a file format
which includes information about Z-coordinates in a direction of
height for individual X- and Y-coordinates, respectively. After
entering a print pattern such as a character string "ABCDEFGHIJKL"
in the Text box 204b of the Print Pattern dialog box shown in FIG.
49, the Profile Setting dialog tab is enabled to select a ZMAP
option in the Print Category menu box 205 which functions as the 3D
data input means 3b. When choosing the ZPAM in the Print Category
menu box 205, a ZMAP File Name box 292 appears. Then, the user
specifies a file name of a desired ZMAP in the ZMAP File Name box
292. Otherwise, when pressing a REF button 293 on the right-hand
side of the ZMAP File Name box 292, an Open File dialog box 294
shown in FIG. 51 appears to list available file names (in this
embodiment, only one file name is listed). Then, the user can
select a ZMAP file (e.g. dolphin.MD3) which the user wants to
import. Whereupon choosing the ZMAP file, the chosen file name
"dolphin.MD3" is indicated in the ZMAP File Name box 292 as shown
in FIG. 52.
In this state, the edit display window 202 displays the print
pattern "ABCDEFGHIJKL" pasted to the three dimensional profile
represented by the three dimensional profile data defined by the
ZMAP file. When the user wants to look a 3D representation, the
edit display window 202 is altered from the 2D view mode to the 3D
view mode shown in FIG. 53 by pressing the View button 207A of the
floating tool bar 207. As a consequence, the print pattern
"ABCDEFGHIJKL" pasted to a specified part of the work surface is
displayed in three dimensions in the edit display window 202. Like
this, the print pattern "ABCDEFGHIJKL" can be confirmed both in two
dimensions and three dimensions. Further, concurrently with
specifying a ZMAP data file, a ZPAP Display command box 207D is
enabled as shown in FIG. 52. When enabling the ZPAP Display command
box while the edit display window 202 is in the 3D view mode as
shown in FIG. 53, the edit display window 202 displays the printed
print pattern "ABCDEFGHIJKL" laid on a representation (dolphin) of
the three dimensional data defined by the specified ZMAP file as
shown in FIG. 54. This feature enables users to visually confirm a
general appearance of printing.
Pasting of the print pattern to the work is achieved so that a
print pattern in an orthogonal projection on a three dimensional
work surface can be recaptured in a right pattern when viewed in a
specific direction, e.g. head-on, as shown in FIGS. 53 and 54, in
other words, so that the print pattern "ABCDEFGHIJKL" displayed in
the edit display window 202 in the 2D view mode as a consequence of
specifying the file name in the ZMAP File Name box 292 as shown in
FIG. 52 remains unchanged even though the edit display window 202
changes from the 2D view mode (FIG. 49) to the 3D view mode (FIGS.
53 and 54), and vice versa. In this instance, three dimensional
information about the print pattern is generated by adding
information about a height (Z coordinate) at a point on the ZMAP
which has having X and Y coordinates to two dimensional information
about a point of the print pattern which has X and Y coordinates
corresponding to those of the ZMAP point. Because this method uses
the two dimensional information about the print pattern on its own
and refers to only height information held in the ZMAP file, data
processing for changing the print pattern from two dimensional to
three dimensional is facilitated. As a consequence, the data
conversion is achieved with a reduced load and a high speed. In
particular, when a work has a complicated shape, this method is
advantageous in light of throughput capacity and speed.
Furthermore, because of accurate appearance of a print pattern such
as a symbols and characters, this method is advantageous to an
application where a printed pattern has to be read or recognized in
a definite direction for identification. For example, even when
printing a symbol such as a barcode on a curved surface, it is
avoided that a printed barcode is misread due to distortion at an
end portion of the printed barcode. As a consequence, print
patterns are read by optical character readers or optical barcode
readers at a high read rate.
In the method of choosing an elemental profile and specifying
parameters of the elemental profile, a print pattern is pasted to
an elemental pattern developed in plan. That is, a two-dimensional
representation of a print pattern in the edit display window 202
changes as shown in FIGS. 37 and 38. This representation is
favorable for an application where a printed pattern is read or
recognized in indefinite directions, for example an application
where a print pattern which does not always need to be recognized
for identification like a date of manufacture and a serial
number.
As just described above, the Print Category menu box 205 performs
the function of switching from the elemental profile specification
via the elemental profile specifying means 3a to the ZMAP file
specification function via the 3D data input means 3b, and vice
versa.
FIGS. 55 to 70 show a procedure for creating ZMAP data from a
three-dimensional profile data file provided in the form of general
purpose data file in the following procedure. Three-dimensional
profile data files can be prepared by the use of commercially
available computer programs such as a 3D-CAD program and a 3D-CG
program and written in the file format of STL (Stereo Lithography)
in this embodiment. The STL file format, which has a data structure
in which an object is represented by an aggregation of a number of
triangular planes, facilitates data handling. The file format may
be of course selected from available file formats general-purpose
file formats such as DXF, IDES, STEP and file formats exclusive to
specific application software such as DWG, DWF, CDR and AI. It is
practicable to enclose a file converter for converting a
three-dimensional profile data file into a STL data file. The three
dimensional data setting program reads in the STL data file of
three-dimensional profile.
When choosing a "ZMAP Edit" command in an edit menu, a ZMAP edit
window 300 appears in the screen as shown in FIG. 55. The ZMAP edit
window 300 includes a view window 301 at the left-hand side which
displays a three dimensional representation of three-dimensional
profile data and a Posture Adjustment dialog box 302 at the
right-hand side in which a posture of the three dimensional
representation to be displayed in the view window 301 is specified.
When choosing an "Open STL File" command in a file menu, an STL
File select dialog box opens. Then, the user specifies a disk to
open a list of STL files in the dialog box and specify an STL file
which the user wants. FIG. 56 shows the ZMAP edit window 300 with
the specified STL file opening in the view window 301. In this
state, a STL Display button 303 is made pressed to indicate that
the specified STL file is displayed in the view window 301. In this
embodiment, a default position of a three-dimensional profile data
is such that an extreme end of a representation of the
three-dimensional profile data is at original coordinates. However,
it is allowed to change the default position. The representation
(object) can be displayed in a desired posture which the STL data
file is wanted to be converted into a ZMAP data file by changing
parameters (coordinates and angles of rotation) for defining a
posture of a representation of the STL data file. For example, when
specifying -60 mm in an X Coordinate box 304 in the Posture
Adjustment dialog box 302 shown in FIG. 56, the object translates
-60 mm left in the view window 301 in an X-Y coordinate plane as
shown in FIG. 57 and or in X-Z coordinate plane as shown in FIG.
58. In the same way, the object translates 10 mm vertically up as
shown in FIG. 59 or down as shown in FIG. 60 by specifying 10 mm or
-10 mm in a Z Coordinate box 304 in the Posture Adjustment dialog
box 302 shown in FIG. 58, respectively. Further, the object
translates 50 mm upward as shown in FIG. 61 by specifying 50 mm in
a Y Coordinate box 304 in the Posture Adjustment dialog box 302
shown in FIG. 57. X, Y and Z coordinates are specified by entering
numeral values in the X, Y and Z Coordinate boxes 304, or otherwise
by using scroll arrow keys 305, respectively. X and Y coordinates
are changed by up and down and right and left arrow keys 305a
arranged crosswise, and a Z coordinate is changed by up and down
scroll arrow keys 305b. In this way, the user can visually confirm
the object moving it in the view window 301. In addition, the
object can be rotated independently around X-, Y- and Z-axes in
view window 301 by specifying angles of rotation in a Rotational
Angle dialog box 306 in the Posture Adjustment dialog box 302 as
shown in FIGS. 62, 63 and 64, respectively. Angles of rotation
around X-, Y- and Z-axes are specified by entering numeral values
in the X, Y and Z Rotation boxes 306, or otherwise by using scroll
slide keys 305, respectively.
As shown in FIGS. 65, 66 and 67, it is practicable to display
boundary representations KM for indicating printable zones in X, Y
and Z directions in the view window 301. The boundary
representations KM indicating X, Y and Z directional printable
zones are displayed by choosing X, Y and Z direction check boxes in
a Printable Zone Display dialog box 307. The X, Y and Z directional
printable zones can be displayed independently or concurrently.
This boundary representing function enables users to visually
ascertain whether a representation of the three dimensional data
falls in X, Y and Z printable zones adjusting a layout of the
object. In this instance, a view point can be changed by scrolling
the view window 301 and/or rotating an object in the view window
301. For this purpose, scroll bars of the view window 301 are
functionally altered between view window scrolling and object
rotation. This functional alteration of the scroll bars is
performed by enabling a Rotation/Scroll button 308. Further, the
ZMAP edit window 300 may have a simple function of modifying a STL
data file such as alteration of expansion/contraction ratio,
trimming and the like.
When a posture of the representation of the three dimensional
profile data is determined, the profile data is converted into a
ZMAP data file. Specifically, when clicking and enabling a ZMAP
Display button 310 in the Posture Adjustment dialog box 302, a
confirmation dialog box appears to seek confirmation as to a
conversion into a ZMAP data file. In this confirmation dialog box,
an inquiry "Convert into ZMAP. Approve ?" is shown. When choosing
an OK button for approval, STL data file is converted into to a
ZMAP data file and, as a consequence, a ZMAP data file representing
an object such as shown in FIG. 68 is created. Since the ZMAP data
file contains information about height representing one Z
coordinate for X and Y coordinates of a point in an X-Y coordinate
plane, data representing a portion of the object below the X-Y
coordinate plane is lost, so that only a portion of the object
above the X-Y coordinate plane is displayed as shown in FIG. 68.
Because the laser processing system is incapable of processing the
back side of a work, only data representing an upper half of the
work is sufficient. However, when it is required to print the
backside of a work, the three dimensional profile data shown in
FIG. 62 is rotated around, for example, the X-axis by 180.degree.
so that the object turns upside down as shown in FIG. 62 and then
converted into ZMAP data shown in FIG. 69. While the view window
301 is in the state of ZMAP display, the ZMAP Display button 310
remains pressed until it is pressed and disabled. As a consequence,
the ZMAP Display button 310 serves both as a command button for
execution of data file conversion and a label indicating a content
displayed in the view window 301. When the STL Display button 303
is pressed and disabled while the ZMAP Display button 310 remains
enabled, the display in the view window 301 returns from a
representation of the ZMAP data to a representation of the STL data
display. Accordingly, the STL Display button 303 allows users to
cancel and redo operation of data conversion, and to save the STL
data file. After confirming it on the view window 301 that the
three dimensional ZMAP data correctly represents an intended work
surface, the ZMAP data file is saved in a desired directory by
choosing a Save As ZMAP command in the file menu and naming it. In
this way, a print pattern is three-dimensionally converted by
specifying the ZMAP data as three dimensional data representing a
print area.
The three-dimensional conversion of a print pattern based on a
specified ZMAP data is achieved as follows. After entering a
character string "ABCDEFGHIJKLM" in the Text box 204b as shown in
FIG. 49 and choosing ZMAP in the Print Category box 205 as shown in
FIG. 52, a desired ZMAP data file (dolphin M3D) is chosen by
specifying its file name in the ZMAP File Name box 292. As a
consequence, the print pattern, i.e. the character string
"ABCDEFGHIJKLM" is changed in three dimensions. At this time, the
character string "ABCDEFGHIJKLM" is still displayed in A X-Y
coordinate plane as shown in FIG. 52. When choosing the View button
207, the edit display window 202 is altered from the 2D view mode
to the 3D view mode so as thereby to display the print area in
three dimensions as shown in FIG. 53. In this way, the print
pattern is mapped on the print area so as to equal out in
appearance with the print pattern viewed from above shown in FIG.
52. Further, when enabling the ZPAP Display command box 207D, view
window 301 displays the work defined by the ZMAP data in three
dimensions with a three dimensional profile of the print pattern
overlapped thereon as shown in FIG. 54. Similarly, when choosing a
ZMAP data file representing a work upside down shown n FIG. 69, the
print pattern is three dimensionally changed as shown in FIG. 70.
In this way, the view window 301 can be altered from a display of
the print area only to a display of the overall profile of the
work, and vice versa, during setting operation. The user can adjust
a position of the three dimensional data in which the print pattern
is pasted.
When displaying a printing area specified on a three-dimensional
work surface in three dimensions together with the work surface
profile, it is visually checked up whether the printing area falls
in an appropriate printable location relative to the work surface.
A work surfaces is differently colored between a work surface area
upon which a laser beam impinges at angles in a predetermined range
for appropriate print quality (a printable work surface area) and a
work surface area upon which a laser beam impinges at angles and is
expected to be printable but defective in print quality (a
defective printable work surface area). Specifically, the printable
work surface area remains uncolored, and the defective printable
work surface area is colored red. In this way, it is visually
checked up on whether a specified print area falls thoroughly
within a printable work surface area and which part of a specified
print area cuts across a defective printable work surface area even
partly. In the case where a work surface including a print area is
at a far side from laser irradiation, the print area is hidden in
the edit display window 202 in the 3D edit mode so as thereby to
indicate that the specified print area is unprintable (an
unprintable work surface area). This function signals the user a
relative position of the work print area with respect to a work
surface and prompts the user to correct the print area. This
function is not linked to the above means. Any visual checking
means known to those skilled in the art can be available for
indicating a printable work surface area, a defective printable
work surface area and an unprintable work surface area. For
example, these work surface areas may be indicated by text messages
on the edit display window 202, by voice messages or by an alarm.
It is practicable to indicate one of the three situations, for
example an unprintable work surface area, which the user wants to
know.
In this instance, an incident angle of laser beam which
distinguishes a printable work surface area and a defective
printable work surface area from each other is specified by a
default initial angle, or otherwise may be specified by entering
another angle in an entry box additionally provided in the edit
display window 202. Specifically, laser processing of a work
surface is limited and made difficult depending upon irradiation
angles and lowers its precision as an irradiation angle .theta.
with a normal line of the work surface comes close to 90.degree.. A
critical irradiation angle or higher limit angle (processing
limitation angle) is ordinarily fixed to 60.degree. and may be,
however, adjusted by the user.
In this way, it arises in three-dimensional printing according to
work profiles and relative position between a work surface and a
laser beam that some work surface areas are unexposed or only
insufficiently exposable to the laser beam, in other words,
unprintable or only defectively printable. Therefore, it is
practicable to calculate a printable work surface area based on
these factors and to caution the user to try another setting when
representation of laser printing data falls within an unprintable
work surface area. This calculation is performed in the
arithmetical and logic unit 80. The arithmetical and logic unit 80
enables the defective surface area detection means 80B to detect a
defective work surface area by performing calculations, the
processing condition adjusting means 80C to adjust printing
conditions so as to make the defective printable work surface area
well printed, the highlighting means 80I to highlight the defective
printable work surface area detected by the defective surface area
detection means 80B so as thereby to display it differently from a
printable work surface area, and the warning means 80J to provide a
warning that a print pattern set by the processing condition
setting means 3C cuts across even partly a defective printable work
surface area.
The highlighting means 80I highlights a defective printable work
surface area of a work surface in the edit display window 202. As
shown in FIG. 39, a work surface area close to a root of a columnar
work surface which is only defectively printable due to a narrow
angle of a laser beam incident thereupon is displayed in red.
Further, an unprintable work surface area is a work surface area
which is at a far side from laser irradiation and, thus, isolated
from laser irradiation. The defective printable work surface area
and the unprintable work surface area are calculated by defective
surface area detection means 80B. When a specified print pattern
cuts across even partly an unprintable work surface area and is
consequently unprintable, the warning means 80J makes the print
pattern disappear from the edit display window 202 so as thereby to
prompt the user to try another layout. For example, the warning
means 80J makes a print pattern hidden when the print pattern cuts
across even partly a work surface area specified at a far side from
laser irradiation and displays a print pattern in red when it falls
on a defective printable work surface area. In this way, work
surface areas are categorized not simply by printable and
unprintable, but a plurality of grades of print quality such as
good quality, flawed quality and unprintable. This categorization
of work surface area provides the user with detailed information
about layout.
FIGS. 71 and 72 show print patterns, i.e. barcodes K, which cut
across even partly unprintable work surface areas. Therefore, the
warning means 80J hides the print pattern in the edit display
window 202. In this event, the printing position is adjusted so as
to lay the print pattern in a printable work surface area. On that
account, as shown in FIG. 71, the 3D Setting tab 204i is enabled to
open the Layout dialog box 208 in which a print start angle is
changed from -90.degree. (a default angle) to -120.degree.. As a
result, the barcode is displayed as shifted as shown in FIG. 36. In
this way, a print pattern is set up by adjusting a print start
position, a work surface area, a narrow space width, a bar
thickness and the like so as thereby to be accurately printed. This
adjustment may be performed not manually but automatically by the
processing condition adjusting means 80C.
Referring to FIG. 73 shows a Settings dialog box for setting laser
parameters in which the function of highlighting an unprintable
work surface area by the highlighting means 80I can be enabled and
disabled. The function of displaying an unprintable work surface
area is disabled by clearing an Enable Unprintable Work Surface
Area Display check box in the Settings dialog box. In the Settings
dialog box, laser parameters such as a focal distance, an effective
range in a Z direction and an effective angle (a critical
irradiation angle) are checked up on and adjusted as appropriate.
In addition, a printable work surface area can be specified in size
and position when a defective printable work surface area and an
unprintable work surface area are detected by the defective surface
area detection means 80B. On that account, the warning means 80J is
enabled to display data on coordinate limits of a work surface area
and a maximum printable size in the display unit 82. A numerical
display of settings can be utilized as an indicator of resetting by
the user and provide easy-to-operate circumstances.
The warning means 80J hides a print pattern in the an object
display section 83 when the print pattern detected by the defective
surface area detection means 80B cuts across at least partly a
defective printable work surface area. In the past, in order to
ascertain that printing work will not be performed correctly by a
laser processing machine capable of processing in three dimensions
due to improper printing conditions, the only way was to actually
print for visual checking, or otherwise, a way to ascertain
printability by the controller of a laser marking machine after
transferring data on printing conditions into the memory of the
controller and extracting the data. Printing conditions are
determined by specifying a profile of work (e.g. column, cone,
sphere, etc.) and a print pattern (e.g. a character string) to be
printed on the work. Since a printable pattern size (printable work
surface area) depends on parameters such as a work size and a
diameter, it is necessary to specify a print pattern smaller than
these parameters. However, in the past, users could not know
whether a print pattern falls within a printable work surface area
during printing conditions setting operation, and, as a
consequence, the best the user could do was to check for errors
only after transfer and extraction of data on the printing
conditions which are determined by specifying a work profile and a
print pattern. Since transfer and extraction of data is a somewhat
time consuming operation, the conventional approach is
inconvenient.
On the contrary, according to the present invention, the warning
means 80J realizes the function of informing the user whether
printing is possible or not and whether the print result will be
good or bad during printing conditions setting operation. Practical
informing means is to indicate a printable pattern size at the
instant of specifying a work profile, a print pattern size at the
instant of setting it, or a work profile and a print pattern
combined together.
FIG. 74 shows an example of a representation of a printable pattern
size in the object display unit 83 at the instance of specifying a
column as a work surface area. Therein print will be degraded due
to a narrow incident angle at which a laser beam impinges and is
detected as a defective printable work surface area by the
defective surface area detection means 80B and displayed in red by
the highlighting means 80I. Coincidentally, a printable work
surface area is displayed by a frame K1 showing a pattern size
printable on a columnar work surface by the warning means 80J. The
frame K1 can be represented by a line different in color, thickness
and/or style from an object for enhanced visibility and distinction
of the printable work surface area.
FIG. 75 shows an example of a representation of a print pattern
size in the object display section 83 at the instance of specifying
it. When a size of a print pattern is specified by the user, a
frame K2 having the same size as the print pattern is displayed on
a work surface. Accordingly, a print pattern size currently
specified is reflected in the representation in the object display
section 83 for immediate visual checking. It is checked up by the
user that there is no mixture between the defective printable work
surface area colored red and the frame K2 and that print is
expected to be made appropriately.
FIGS. 76 and 77 show examples of representations of a print pattern
and a work surface in combination in the object display section 83.
Because the representation includes a print pattern, such as a
character string "ABC", as well as a frame K3 indicating a print
pattern size, the user can ascertain a virtually printed print
pattern with enhanced visibility. In FIG. 75, it is checked up that
the character string "ABC" in the frame K3 does not cut across even
partly the defective printable work surface area colored red. On
the other hand, in FIG. 77, it is checked up that the character
string "ABC" in the frame K3 cuts across even partly the defective
printable work surface area colored red. When such an interference
between a print pattern and a defective printable work surface area
occurs, it is practicable to display a text message as shown in
FIG. 91.
Referring to FIG. 78, the warning means 80J displays a precomposed
written message such as "Caution: Printing conditions you set are
improper" in the object display section 83. It is practicable to
indicate recommendable values for another setting. FIG. 79 shows an
example of a directive written message such as "Caution: Set
between
.smallcircle..smallcircle..about..smallcircle..smallcircle." for a
guide to appropriate settings. Examples of the directive written
message include "Caution: Set printing position between
.smallcircle..smallcircle..about..smallcircle..smallcircle.",
"Caution: Set character size less than .smallcircle..smallcircle."
and the like. It is also allowed to use any combination of these
directive written messages. These written messages offer a useful
guide to another setting and provide easy-to-operate circumstances.
These written messages may be of course replaced with voice
messages or warning sounds.
The function of the defective surface area detection means 80B
shown in FIG. 13A will be described in detail below. It is not
improbable that a work surface includes an area where defective
processing is made depending upon work profiles, work transfer
speeds, scanning speeds of a laser beam. In the case where a
processing pattern is accidentally specified in the defective
printable area, since there are provided no means for informing of
existence of a defective printable work surface area, defective
prints and printing errors occur. Therefore, it is essential to
carry out visual print quality inspection and withdrawal and
disposition of defective works which is quite troublesome and
wasteful. For these reasons, in this embodiment, the user is given
a warning at the instant of specifying a print pattern that the
print pattern is expected to be made, partially or completely, in a
defective printable work surface area, or is given a warning that
printing errors occur when actually printing. This warning function
is realized by the defective surface area detection means 80B. In
this instance, the term "defective printable work surface area"
which is detected by the defective surface area detection means 80B
as used herein includes an "unprintable work surface area." as well
as a defective printable work surface area.
FIG. 80 shows how the defective surface area detection means 80B
detects a defective printable work surface area of a cubic work W.
In this embodiment, a laser beam LB scans a printing plane SP at a
fixed distance K from a reflection plane MP. First and second scan
mirrors M1 and M2 have axes of rotation coinciding with X- and Y
axes of the reflection plane, respectively, are located at a
distance L from each other in the Y-direction, and inclined at an
angle of .theta.1 in the X-direction. When focusing the laser beam
LB at a point A having coordinates of X, Y and Z, the following
equation hold: Tan
.theta..sub.1=X/{[(Y.sup.2+(K-Z).sup.2].sup.1/2+L} where a vector
of the laser beam LB is expressed by the following equation: (X-L
Tan .theta..sub.1, Y, Z-K) Hence,
x=Xt-LXt/{[(Y.sup.2+(K-Z).sup.2].sup.1/2+L}+X y=Yt+Y z=(Z-K)t+Z
With the substitution Tan .theta..sub.1, x, y and z are expressed
as follows: x=(X-L Tan .theta..sub.1)t+X y=Yt+Y z=(Z-K)t+Z
Whether any point A (X, Y, Z) is impinged by the laser beam LB, in
other words, whether any point is shadowed from the laser beam LB
and involved in a defective printable work surface area, depends on
whether lines x, y and z have an intersecting point with the work
surface. Therefore, the defective surface area detection means 80B
detects a defective printable work surface area by calculating x, y
and z from the above equations. Although the above description is
directed to the case where the work remains stationary for
simplified explanation, the defective surface area detection means
80B is enabled to detect a defective printable work surface area of
a work which is moving by performing calculations coupled with a
moving distance from time to time.
Concerning defective printing due to difference in scanning speed
in X, Y and Z directions, since a Z-axis scan mirror operates at a
scan speed relatively lower than X-axis and Y-axis scan mirrors.
This fact makes a controversial impact on processing of an inclined
work surface. In this case, when inclinations of the X- and the
Y-axis with the Z-axis are greater than a predetermined
inclination, it is determined that print is expected to be made
defective. Defective print due to a difference in scan speed can be
eliminated by adjusting printing parameters so as to lower scan
speeds of the X- and the Y-scan mirrors. This is because the
defective print is caused in some cases by the fact that the Z-axis
scan mirror can not follow the Z-axis scan mirror. This scan speed
adjustment function can be performed by the processing condition
adjusting means 80C.
The processing condition adjusting means 80C calculates available
processing conditions based on an angle of inclination of a work
surface, a ratio of X.Y component relative to Z component, a scan
sped of the Z scan mirror, a moving speed of the work, etc. The
calculated processing conditions can be displayed on the display
unit 82. The user can try another setting in reference to the
calculated conditions. Otherwise, the processing condition
adjusting means 80C may be adapted to specify processing conditions
automatically. In this case, since processing conditions are
collectively specified, the user is less pressed to specify
processing conditions and precise processing is realized
irrespective of a defective printable work surface area. Similarly,
in the case where defective print occurs due to variations in scan
speed of X- and Y-scan mirrors, the defective print can be
eliminated by harmonizing the scan speeds of the scan mirrors with
one another.
When the defective surface area detection means 80B detects a
defective printable work surface area, the highlighting means 80I
displays a defective printable work surface area and a printable
work surface area differently so as to enable the user to get hold
of the defective printable work surface area visually. In order to
display these defective printable work surface area and printable
work surface area differently, it is practicable to display the
individual work surface areas in a linear gradient pattern, a gray
scale pattern, a shading pattern or the like, as well as differing
in color, for distinction between them. When printing by use of a
palette, defective printable work surface areas differ from one
another according to works as shown in FIG. 71. In such a case, the
defective surface area detection means 80B detects a defective
printable work surface area by work by performing calculations, so
that the defective printable work surface area is distinctly
displayed on the display unit 82 by the highlighting means 80I.
FIG. 40 shows an Environment Configuration window 210 including a
3D Environment Configuration dialog box 210A including various
options and a Preview Window 210B which is used to specify a laser
beam traveling path to a work. In the Preview window which is
similar to the edit display window 202, a laser beam LB is
displayed together with a marking head icon MK and a work as close
as possible to the way it will appear in the edit display window
202 when specified. This function makes it easy for the user to get
hold of a printing direction relative to a defective printable work
surface area. The iconic representation of the marking head MK
appears in the preview window 210B by default and disappears
therefrom by clearing a Display Marker check box 210a in the 3D
Environment Configuration dialog box 210A. The object in the
preview window 210B is also displayed in three dimensions in the
head display section 84 of the display section 83. It is enabled to
display X, Y and Z coordinate axes in the edit display window 202
as shown in, for example, FIG. 40 for the purpose of easy
coordinate orientation. The X, Y and Z coordinate axes may be
different in color for clear visible distinction. In FIG. 40, the Z
axis is brought into line with a laser beam path. Display of X, Y
and Z coordinate axes makes a spatial localization of the marking
head relative to a work. The X, Y and Z coordinate axes can be
removed from the edit display window 202 by choosing the Display
Axes check box 210b in the 3D Environment Configuration dialog box
210A. In this embodiment, the X, Y and Z coordinate axes appear or
disappear when choosing or clearing the Display Axes check box
210b.
It is of course a design choice to display or hide the X, Y and Z
coordinate axes individually. It is also practicable to display one
or more reference lines, besides the X, Y and Z coordinate axes.
For example, when printing on an area close to a root of a columnar
work surface, it is practicable to draw a reference line along a
side at the root for clarity of a base position. Such a reference
line can be specified by coordinates and a direction of vector. The
marking head in the edit display window 202 is displayed in the
form of an icon MK having the same appearance and color as a real
marking head. However, it is preferred that the marking head icon
has a back side different in color from a front side. For example,
the marking head icon MK colored in ash gray at the front side has
a white back side in FIG. 41 and is colored at a back side in
different color from the front side in FIG. 40. Such a color
pattern may be optional and is advantageous for the user to get
hold of a position of the marking head when varying the view point.
FIG. 82 shows a 3D Color Pattern dialog box 210C which appears when
enabling a Color Pattern tab in the Environment Configuration
window 210. The user can selectively specify colors and pattern
elements in details in the preview window 210B. The pattern
includes any style such as solid lines patterns, broken lines
patterns, fill color patterns, hatching patterns and the like.
FIGS. 83 and 84 show a 2D Environment Configuration dialog box 210D
and a 2D Color Pattern dialog box 210C, respectively. The
Environment Configuration window 210 can be disappeared and/or
closed by pressing a close button.
In this way, the user can get hold of a physical relationship
between the marking head and a work surface by displaying them
together in three dimensions. As a consequence, the user can
visually checks up on the representation of settings with ease and
find and correct setting mistakes. In the above embodiment, the
marking head moves and changes in position correspondingly to
movement of a work surface and a shift in view point In the edit
display window 202, an object can be zoomed, magnified or
demagnified, in the 2D edit mode, and is, however, fixed at a
default magnification. It is possible to display the marking head
always at a fixed magnification irrespectively of magnification or
demagnification of a work because the marking head is displayed for
the primary purpose of orientation thereof. This lets the user keep
track of the marking head even when a work is demagnified. Further,
as the description is directed to printing of a work remaining
stationary in the above embodiment, a 3D working area is centrally
located in the edit display window 202 especially in the 3D edit
mode. However, as described later, it is possible to enlarge the 3D
working area for printing of a moving work so as to provide a large
substantial area for a printable work surface area. This enables
the user to check up on settings with ease. In particular, in the
case where an elongated work moves in its longitudinal direction,
the work is displayed in full view within the window screen so that
it is quite easy for the user to get hold of the complete work
without scrolling the window screen up and down.
In this way, the user can get hold of a physical relationship
between the marking head and a work surface by displaying them
together in three dimensions. As a consequence, the user can
visually checks up on the representation of settings with ease and
find and correct setting mistakes.
In the above embodiment, the marking head moves and changes in
position correspondingly to movement of a work surface and a shift
in view point In the edit display window 202, an object can be
zoomed, magnified or demagnified, in the 2D edit mode, and is,
however, fixed at a default magnification. It is possible to
display the marking head always at a fixed magnification
irrespectively of magnification or demagnification of a work
because the marking head is displayed for the primary purpose of
orientation thereof. This lets the user keep track of the marking
head even when a work is demagnified. Further, as the description
is directed to printing of a work remaining stationary in the above
embodiment, a 3D working area is centrally located in the edit
display window 202 especially in the 3D edit mode. However, as
described later, it is possible to enlarge the 3D working area for
printing of a moving work so as to provide a large substantial area
for a printable work surface area. This enables the user to check
up on settings with ease. In particular, in the case where a long
work moves in its longitudinal direction, the work is displayed in
full view within the window screen, it is quite easy for the user
to get hold of the work thoroughly without scrolling the window up
and down.
FIG. 85 shows the edit display window 202 with the 3D Setting tab
204i enabled in the Profile Setting dialog box chosen by. When
enabling a Print Block Profile-Layout tab 211, a Details Setting
dialog box 212 appears for letting the user specify details of a
block pattern including coordinates of a base position, angles of
rotation and details of profile of a block pattern. When a columnar
work surface is chosen, a radius of a column and a print side,
inner or outer, are specified in the Block Pattern Layout dialog
box 212.
FIG. 86 is a flowchart illustrating a procedure of processing
pattern creation which is achieved by the processing data
generation means 80K during execution of the laser processing data
setting program. In first step S21, a processing pattern is set up
by entering a character string through the processing condition
setting means 3C and specifying an encoding pattern type.
Specifically, as shown in FIG. 14 by way of example, after choosing
Character String in the Print Category menu box 204a to show the
Print Pattern input dialog box 204, the user types numerical
characters "01234 . . . 789" in the Text box 204b and then chooses
a print pattern type, i.e. "2D Code" in the Character Data Type box
204d and a print pattern, i.e. QR Code, in the Type menu box 204q.
The arithmetical and logic unit 80 makes calculations based on the
information thus specified to create a print pattern. The created
print pattern appears in the form of 2D representation on the edit
display window 202. In this example, although the QC code is
automatically created as a print pattern according to information
about a character string entered through the processing condition
setting means 3C, an intended print pattern may be chosen from a
set of print pattern templates or importing an intended print
pattern from other files and pasting it in the edit display window
202. In subsequent step S22, profile information is gained through
the processing condition setting means 3C. Specifically, when
enabling the 3D Setting tab 204i of the Print Pattern input input
dialog box 204 shown in FIG. 14, a Print Category box 205 and the
Profile menu box 206 appears as shown in FIG. 37. Then, a column is
chosen as an elemental profile In the Profile dialog box 205. As a
result, the edit display windows 202 changes an object from
plane-shaped to column-shaped as shown in FIG. 38. When changing
the edit display window 202 to the 3D view mod, the columnar work
with the QR code laid thereon changes to 3D representation in the
edit display window 202 as shown in FIG. 39. In this way, 3D
representation of a print pattern appears in the edit display
window 202 in the 2D view modes by inputting print pattern
information in step S21, and is subsequently converted into 3D
representation in the same window 202 but in the 3D view mode by
inputting profile information in step S22. The user can visually
take a change in print pattern In the processing pattern creation
sequence flowchart, the steps S21 and S22 may be replaced with each
other. Once processing data has been acquired in the form of 3D
spatial coordinate data, a fine adjustment is made in layout and
position in the Z-direction as appropriate. The fine adjustment can
be achieved by the use of scroll bars or a mouse wheel.
The resultant laser processing once provided in the above sequence
is transferred to the control unit 1A of the laser processing
system shown in FIG. 12 when pressing Transfer Readout command
button 215 below a lower window border. In the memory of the
control unit 1A, the laser processing data is expanded and
overwritten.
The laser processing system performs printing based on the laser
processing data. It is practicable to make test printing prior to
actually printing in order to confirm whether printing is possible
or not and whether the print result will be good or bad. A
plurality of printing patterns can be specified for one work
surface or individually for a plurality of work surfaces by
repeating the same procedure. Further, a print patterns may be
specified
The moving work printing follows procedural steps of (1)
determining a print pattern; (2) setting printing conditions for a
moving plane work; (3) starting print; and (4) adding a moved
distance of a work to X and Y coordinates of the print pattern. The
printing conditions for a moving plane work which include at least
a moving direction, a moving condition, and/or a printing area will
be described in order below. In FIGS. 87A and 87B schematically
showing the concept of moving work printing in two dimensions, the
plane work WP moves towards the right in the drawing. In a Line
Setting window 240 shown in FIG. 88 where a marking head is shown
in plane and cross section, a Move Direction dialog box 241 is
opened to let the user specify an X/Y direction and/or a Z
direction of movement of the work WP. In this instance, a bearing
of a line and a moving direction of the line are chosen in the Move
Direction dialog box 241. The visual optionality of conditions
makes the user to easily gain an understanding of relative position
between the marking head and a work, so as thereby to achieve
setting without errors. In the case where a direction of a print
pattern is orthogonal with a moving direction of the marking head,
an up or a down arrow is chosen in the Move Direction dialog box
241. The moving condition means a control mode of work speed,
namely an open loop control for maintaining the work speed constant
or a feedback control and is a choice between the two.
The printable work surface area is defined by moving ranges of a
scanner correspondingly taken along X- and Y-axes of a plane
coordinate system. The moving ranges of scanner is designed so that
the coordinate plane displayed in the edit display window 202 such
as shown in FIGS. 14 and 39 corresponds to a maximum printable work
surface area. The user can automatically define a printable work
surface area by specifying a print pattern within the coordinate
plane.
When specifying processing conditions for a moving plane,
positional X and Y coordinates of a laser beam after a start of
printing a given print pattern can be calculated and it can be
decided whether the laser beam should be turned on or off at the
individual positions. The positional coordinate of a laser beam is
calculated by adding a moving distance of a work in a moving
direction to a coordinate of a substantial point forming part of
the print pattern in the moving direction. In the example shown in
FIG. 87A, since the work moves in an X-direction, the positional
coordinate of a laser beam is calculated in terms of X-direction
and is left intact in terms of Y-direction. The moving work
printing is well suited for works which are rotating or moving in
three dimensions. In such a case, the moving work printing follows
the same procedural steps as the moving plane work printing.
FIG. 89 is an edit display window 202 with the Print Pattern input
dialog box 204 in which a Details Setting tab 204j is enabled by
the user. The processing data generation means 80K described above
is adapted to generate processing data based on processing
conditions specified through the processing condition setting means
3C so as to turn out a basic condition for conformation of a focal
point of a laser beam to a work surface. However, it is possible to
set a defocus distance so that the laser beam is intentionally put
out of focus on the work surface. The term "defocus distance" as
used herein shall mean and refer to an offset from a focal position
of a laser beam or a distance between a focal point of a laser beam
and a work surface. In the Details Setting dialog box, the user can
specify a defocus distance which the user wants in a Defocus box
204o which is one of parameters boxes schematically denoted by
204n. The laser beam is focused at the defocus distance specified
by the user above from a work surface if the defocus distance is a
negative value or below from a work surface if it is a positive
value. It is also practicable to set other parameters such as a
spot size of a laser beam on a work surface and a work material. At
this time of specifying one parameter, the processing conditions
set by the user are automatically changed according to the
parameter. As a consequence, the user can easily perform
conditioning through an alteration of a parameter which the user
wants. As shown in FIG. 89, the parameters boxes 204n include a
Working Distance box, a Spot Side box and a Material box. The
working distance is inherent in an in-use laser processing machine
and is automatically set depending upon it by ordinary. The spot
size is specified in percentage with respect to a spot size at a
focal point. The work material is chosen from a pull-down Material
menu 204k appearing when the Material box is chosen. The Material
menu lists various processing purposes such as Steel Print in Black
and Stainless Print in Black, Resin Deposition and Rough Surface,
besides various materials such as ABS Resin, Polycarbonate Resin
and Phenol resin. Selection of a material induces coordination of
power density of the laser beam.
These parameters are dependent on one another. That is, when
adjusting a defocus distance of a laser beam, power density and a
spot size of the laser beam varies correspondingly. Further, when
choosing a work material and a purpose of processing, appropriate
power density is adjusted correspondingly and hence, a spot size or
a defocus distance of the laser beam varies correspondingly.
Therefore, if it was necessary to adjust power density of a laser
power keeping the spot size of the laser beam, the user is required
to specify a desired spot size of the laser beam, and besides
adjusting parameters such as output power of the laser beam and a
scanning speed so as thereby to seek for an appropriate combination
of parameters which causes no change in the spot size of the laser
beam. The adjustment of parameters was performed by another trial
and selected based on the result of actual laser processing of a
work surface, which is quite troublesome and consumes a lot of
time.
In light of the above problem, the laser processing data setting
system 180 of the present embodiment has a relational data base in
the form of a look-up table 5a, listing a number of records of
parameters according to changes in individual parameters, in the
memory device 5A (see FIG. 13). When changing one of the
parameters, an appropriate record is selected from the look-up
table 5a so as to set parameters of the selected record
automatically. Accordingly, the processing condition setting is
completed by changing only a parameter which the user wants to
change. For example, in the Details Setting dialog box opened in
the Print Pattern input dialog box 204 shown in FIG. 89, when
specifying either a spot size or a work material, the remaining
parameters in the Details Setting dialog box are automatically
corrected according to the parameter or the attribute which the
user specified. Even if changing a defocus distance after a spot
size or a work material is specified, the remaining parameters (for
example, laser output power and a scanning speed, etc.) are also
corrected automatically so as to keep the specified parameter, i.e.
the spot size or the work material, unchanged. In this way, as the
user is requested to change only a parameter which the user
intends, a desired result is reached quite easily.
FIGS. 90A and 90B show processed patterns which are formed by
varying a processing parameter continuously during laser
processing. More specifically, FIG. 90A shows a processed work
section of a work W1 on which a sloping groove KS is engraved, and
FIG. 90B shows a processed work surface W2 on which a logo LQ is
printed in brushstroke. These processed patterns KS and LG are
formed by varying a defocus distance or a barn spot of a laser beam
continuously. The processing data generation means 80K adjusts the
remaining parameters automatically following the continuous
variation of the defocus distance so as to keep the remaining
processing conditions unchanged. As a consequence, processing
conditions which are not necessary to be changed remains
unchanged.
FIG. 91 shows an edit display window 202 accompanied by a
Continuous Processing dialog box for setting continuous laser
processing. When choosing a Continuous Processing check box, spin
boxes appears to let the user specify defocus distances or spot
sizes in numeral value. For example, when after choosing a Defocus
Distance check box, defocus distances at start and end positions
are specified in the spin boxes for start and end positions,
respectively. The defocus distance linearly varies in a specified
range. It is practicable to specify a defocus distance for either a
start position or an end position, and an increasing or a
decreasing rate or a change by increment or decrement in place of
the defocus distance for a start position or an end position. When
specifying defocus distances, spot sizes are correspondingly and
automatically specified in spin boxes in reference to the look-up
table 5a in the memory device 5A. In this way, when having a choice
between the corresponding two, the other is automatically
specified, so that the user can change the processing conditions
specified once by specifying only an intended parameter without
focusing attention on dependency relations of the parameters. In
the example shown in FIG. 56, the edit display window 202 and the
3D viewer window 260 display RSS-CC codes responding to a choice of
RSS & CC which the user specified in the Character Data Type
box 204d. In this instance, either an RSS code or a composite code
comprising an RSS code and a micro PDF code arranged adjacently can
be chosen in the Character Data Type spin box 204d. As the
composite code, RSS-24 CC-A has been chosen in the Type menu box
204q. In order to enable the user to enter a describe in the Text
box 204b with ease, it is practicable to display a floating tool
bar including various tools, including special character code
tools, external character tools and the like. As just described
above, the processing data generation means 80K enables the user to
alter settings such as a work material, a processing pattern, a
type of finish, a machining time and the like by changing a beam
size of a laser beam without restraint. The file of the processing
data created according to parameters for processing conditions that
once the user specified is saved under an individual file name at
any time. The processing data file is saved by choosing a File menu
to display a pull-down menu and then choosing Save As menu to open
a File Save dialog box and entering a new file name in a file name
box. The processing data file can be use when the same laser
processing is applied to similar works. It is practicable to use
various data files of all-to-common processing conditions which are
provided previously.
As just described above, the basic process of the programmed laser
processing data setting comprises setting a character string and
its layout as information about a two dimensional print pattern by
use of a user interface for two dimensional setting, and thereafter
setting three dimensional information and its layout for converting
the two dimensional print pattern into a three dimensional print
pattern by use of a user interface for three dimensional setting.
Specifically, information about a print pattern such as a character
string, a barcode, a two dimensional code, a user-defined graphic
and the like and data on a plane layout of the print pattern such
as a size, inclination of the individual characters, line widths
and the like are entered through the user interface for two
dimensional setting. This data entry can be achieved by directly
specifying numerical values or by directly editing an object
displayed in two dimensions on the display screen or window through
mouse operation. Subsequently, information about a three
dimensional pattern and a layout is added to the two dimensional
print pattern by use of the user interface for three dimensional
setting. In order to specify a three dimensional profile, the 3D
Setting tab 204i (see FIG. 38) is opened. When specifying Column in
the Profile menu box 206, a print pattern is changed as attached to
a columnar surface and displayed in plane as viewed from right
above the columnar surface as shown in FIG. 38.
Transformation of the print pattern from a plane view to a three
dimensional view is achieved as follows. In the case of a three
dimensional object such as a columnar surface which is developable
in plane, a print pattern such as a character string set in two
dimensions is regarded as being laid on a developed plane surface.
When creating a three dimensional columnar surface from the
developed plane view, it is easily calculated which position the
character string occupies in the three dimensional work surface.
Further, a front view of the three dimensional character string is
gained by creating a representation view of the columnar work
surface with the character string laid thereon which is viewed
infinitely right above from a surface to be printed and then
excluding information about all but the character string, i.e.
about the columnar work surface, from the representation view of
the columnar work surface. Not exclusively to this way, it is
practicable to project a print pattern set in two dimensions onto a
three dimensional surface in a desired direction or to lay a print
pattern set in two dimensions on a three dimensional surface in
approximate mapping.
A layout of the print pattern set in three dimensions is adjusted
by use of the user interface for three dimensional setting. The
layout adjustment is finely achieved by adjusting a position of the
print pattern displayed in plane on the two dimensional view window
intuitively confirming a solid position of the print pattern on the
three dimensional view window. For the layout adjustment,
information is entered to specify coordinates of a reference
position of a basic profile, an inclination of the basic profile,
distances of characters from the reference position of the basic
profile. This information entry can be achieved by directly
specifying numerical values or by directly editing an object (the
print pattern) on a work surface displayed in two dimensions and/or
three dimensions in the display screen or window. Examples of items
which are possibly specified in the layout adjustment include those
listed in a table shown in FIG. 92.
The processing conditions include information about processing
patterns and information about three dimensional profiles necessary
to convert a processing pattern into a three-dimensional profile
according to the work profiles. Examples of the processing pattern
include character strings, graphics such as barcodes, two
dimensional codes and logos. In mass processing such as printing of
pallets, it is preferred to involve variable numbers such as a date
of manufacture and a serial number in a processing pattern. Such a
processing pattern applied to a work assures traceability of the
work.
FIGS. 93A and 93B are illustrations for explaining a tracking
function of the Z-axis scanner. In the laser processing system for
three dimensionally scanning a work surface with a laser beam to
print the work surface, the Z-axis scanner is enabled to move
following movement of X-axis and Y-axis scanners by correlating a Z
coordinate with X and Y coordinates. Taking printing a quadrangular
pyramidal work shown in FIG. 93A, a Z coordinate of a position on
an oblique plane is correlated with X and Y coordinates of the
position which is represented by a cell of a correlation chart
shown in FIG. 93B. The Z-axis scanner can operate to move a laser
beam spot to a Z coordinate which is automatically determined
according to operation of the X-axis and Y-axis scanners following
the correlation defined by the correlation chart. In general, a
Z-axis scanner is apt to be inferior in responsiveness to X-axis
and Y-axis scanners due to a mechanical difference from the X-axis
and Y-axis scanners. In other words, the Z-axis scanner takes too
long to complete scan operation after receiving an instruction of
scan as compared with the X-axis and Y-axis scanners. Therefore,
when causing the Z-axis scanner to follow up the X-axis and Y-axis
scanners, there occurs a waiting time until the Z-axis scanner
completes its scan operation or it is necessary to reduce speeds of
response of the X-axis and Y-axis scanners, so that, in any case,
it takes a comparatively long time to complete printing.
For that reason, in this embodiment, the Z-axis scanner tracking
function is enabled not regularly but only as needed. Specifically,
as shown in FIGS. 94A and 94B, the Z-axis scanner is caused to
operate as indicated by a heavy solid line and arrows according to
the correlation defined by the correlation chart during substantive
printing and, however, stays in a position to hold the laser beam
spot at a fixed Z coordinate as indicated by a heavy broken line
and an arrow during an interruption of printing. As a consequence,
the Z-axis scanner discontinues its operation during operation of
the X-axis and Y-axis scanners during an interruption of printing,
so that, since the X-axis and Y-axis scanners are allowed to
operate at their potential speeds, an overall printing time is
shortened. For example, it is practicable to output a Z coordinate
correlated with X and Y coordinates during substantive printing and
a fixed Z coordinate independent from X and Y coordinates. The
Z-axis scanner may remains unchanged in position so as to retain
the laser beam spot at a Z coordinate at completion of the last
printing or may operate so as to return the laser beam spot to a
specific Z coordinate such as a Z coordinate upon activation of the
laser marking system, a lowest or a highest Z-coordinate during
printing. Otherwise, the Z-axis scanner may operate so as to move
the laser beam spot to a Z-coordinate for initiation of subsequent
printing. This enables the scanning device to ensure a smooth start
of scanning operation.
FIG. 95 is a flowchart illustrating a control sequence of Z-axis
scanner operation. When operating the Z-axis scanner so as to move
a laser beam spot from a position P1 (Xa, Ya, Za) to a position P2
(Xb, Yb, Zb) (see FIG. 96A), a judgment is made in step S'1 as to
whether irradiation of a laser beam is effected. When the answer is
negative or NO, the Z-axis scanner operates so as to move the laser
beam spot along a path defined by Z-coordinates correlated to X and
Y coordinates in step S'2. More specifically, the Z-axis scanner
operates so as to move the laser beam spot from a Z coordinate Za
to a Z coordinate Zb along a heavy solid line shown in FIG. 96A
following operation of the X and Y scanners for movement of the
laser beam spot from X and Y coordinates Xa and Ya to X and Y
coordinates Xb and Yb, respectively. On the other hand, when the
answer to the judgment in step S'1 is affirmative or YES, the
control logic proceeds to step S'3 where the Z-axis scanner remains
stationary so as there by to allow the laser beam spot to move
directly from a Z coordinate Za to a Z coordinate Zb along a heavy
broken line shown in FIG. 97A while the X and Y scanners operates
so as to position the laser beam spot at X and Y coordinates Xb and
Yb, respectively, when irradiation of a laser beam is resumed for
subsequent printing. In this way, the Z-axis scanner is prevented
from unnecessarily operating and, as a consequence, the X-axis and
Y-axis scanners can operate at high speeds correspondingly.
It is to be understood that although the present invention has been
described with regard to preferred embodiments thereof, various
other embodiments and variants may occur to those skilled in the
art, which are within the scope and spirit of the invention, and
such other embodiments and variants are intended to be covered by
the following claims.
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